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This invention is a divisional application of U.S. patent application Ser. No. 12/856,340 filed Aug. 13, 2010, now U.S. Pat. No. 7,987,623, which is a continuation-in-part of U.S. patent application Ser. No. 12/700,887 filed Feb. 5, 2010, now U.S. Pat. No. 8,028,457, which is a divisional of U.S. patent application Ser. No. 11/934,392 filed Nov. 2, 2007, now U.S. Pat. No. 7,861,451; which claims the benefit of priority to U.S. Provisional Patent Application. Ser. No. 60/905,556 filed Mar. 7, 2007, and this invention is a continuation in part of U.S. patent application Ser. No. 11/652,337 filed Jan. 11, 20007 now U.S. Pat. No. 7,568,304, which is a continuation in part of U.S. patent application Ser. No. 11/485,762 filed Jul. 13, 2006 now U.S. Pat. No. 7,490,429, which is a continuation in part of U.S. patent application Ser. No. 10/725,082 filed Dec. 2, 2003, now U.S. Pat. No. 7,111,424, and U.S. Design patent application ser. No. 29/259,347 filed May 5, 2006 now U.S. Pat. D566,219.
FIELD OF THE INVENTION
The present invention relates to guns and firearms and more particularly to devices, apparatus, systems and methods of using a foldable accessory adapters or folding rail assemblies for allowing a firearm to be supported by various devices such as but not limited to fore grip/gun handle that can have bipod type legs or only a vertical extension, and or other accessories such as a light or a combination fore grip and light to be foldable underneath the firearm.
BACKGROUND AND PRIOR ART
For many years, there has been considerable amount of prior art for fore grips and bipod devices, that date back to pre-20 th century times, with bipods having a familiar appearance, structure and configuration, where the fore grips and bipods are generally kept in a vertical orientation beneath the firearm.
For example, some known prior art includes but is not limited to U.S. Pat. Nos. 271,251; 1,295,688; 1,355,660; 1,382,409; 1,580,406; 2,386,802; 2,420,267; 2,436,349, and 3,235,997. These patents disclose the respective art in relation to bipods, but do not disclose a fore grip or gun handle with a concealable and collapsible bipod. U.S. Pat. No. 6,487,807 describes a tripod gun handle that provides a combination pistol grip and pivotal tripod. An examination of this patent reveals a number of problems with this device, and the most obvious problem is that the tripod legs are positioned on the exterior of the handle when not deployed. If the gun with this device attached was being used in wet or muddy environments, either in a deployed or storage position, the ingress of mud and dirt into and around the handle could result in the deployment and storage of the tripod legs being severely restricted due to the mud or foreign matter. Another problem is that deployment requires the rotation of a disengagement cam to force the legs into their deployed position and then a leg locking assembly is rotated to lock the legs into a locked position. Two separate actions are required to deploy and lock the tripod legs into a locked position.
Another problem with these bipods and leg stands is that the fore grip type stands are generally locked in a fixed position, which means an operator would have to physically move and/or physically raise the stand to adjust the firearm to fire a shot. Such physical movements of having to physically cant, tilt and/or lift the stand would be naturally uncomfortable to the operator. In addition such physical movements can cause the firearm to be held in an unsteady position that makes both a steady and reliable shot at an intended target both difficult and potentially impossible.
Another problem with many firearms having fore grips and bipods is that the fore grips remain in fixed vertical type orientations beneath the firearm at all times. Thus, these firearms can be cumbersome to carry since the fore grip is sticking down which can hit or rub against the sides of the human carrier. Also the fixed vertically oriented fore grips make the firearms difficult to store and transport since the lower extending vertical fore grip takes up valuable space and room during transport.
Attempts over the years have been made to allow for allowing for some folding of portions of firearms. See for example, U.S. Pat. Nos. 4,351,224 to Curtis; 4,625,620 to Harris; 5,074,188 to Harris; 5,085,433 to Parsons; 5,711,103 to Keng; 6,470,617 to Gregory; 6,517,133 to Seegmiller et al.; and 6,763,627 to Kaempe. However, none of these references overcomes all of the problems with the prior art described above.
Thus, the need exists for solutions to the problems addressed above.
The novel invention allows stands such as bipods to be able to fold as desired by the firearm operator.
SUMMARY OF THE INVENTION
A primary objective of the subject invention is to provide devices, apparatus, systems and methods of attaching and using a firearm fore grip/gun handle that can fold up along the firearm when not being used.
A secondary objective of the subject invention is to provide devices, apparatus, systems and methods of a detachable firearm fore grip/gun handle that can fold down to extend vertically below when the firearm is being used.
A third objective of the subject invention is to provide devices, apparatus, systems and methods of using a firearm fore grip/gun handle with extendable bipod legs.
A fourth objective of the subject invention is to provide devices, apparatus, systems and methods of attaching and using a firearm fore grip/gun handle that allows for a light to be attached to the fore grip/gun handle.
A fifth objective of the subject invention is to provide devices, apparatus, systems and methods of incorporating a light into a firearm fore grip/gun handle.
A sixth objective of the subject invention is to provide devices, apparatus, systems and methods of attaching and using a firearm fore grip gun handle with a pivotable light.
A seventh objective of the subject invention is to provide devices, apparatus, systems and methods of attaching and using a firearm fore grip gun handle with a foldable light.
An eighth objective of the subject invention is to provide devices, apparatus, systems and methods of using a folding plate assembly for attaching to existing picatinny rails on a firearm, that can support accessories such as foregrips, lights, and the like.
An ninth objective of the subject invention is to provide devices, apparatus, systems and methods of substituting a folding rail assembly for the existing picatinny rails plate on firearms, where the folding rail plate assembly does not enlarge the existing picatinny rail plate used on firearms.
An tenth objective of the subject invention is to provide devices, apparatus, systems and methods of substituting a folding rail assembly for the existing picatinny rails plate on firearms, that uses less material and is less expensive than a folding plate adapter.
A firearm fore grip adapter having an adapter member, an upper portion on the adapter member for allowing the member to be attachable beneath a firearm, and a lower portion pivotally attached to the adapter member, the lower portion for supporting a fore grip thereon, wherein the fore grip can move between a vertical downward position for supporting the firearm to a folded position with fore grip adjacent to the firearm. The upper portion can be an upper clamp for clamping the adapter member underneath of the firearm.
The upper clamp can include clamp edges for sliding about picatinny rails underneath the firearm. The upper clamp can include compressible clamp edges for clamping about picatinny rails underneath the firearm with a rotatable knob/screw.
The lower portion can include rails for allowing the adapter to attach to detachable fore grip. The adapter can include a pullable button for releasing the pivotable lower portion. The adapter can include a depressible button for releasing the pivotable lower portion. The adapter can include a switch for releasing the pivotable lower portion.
The fore grip can have bipod legs. The fore grip can have a light.
The invention can include an adapter member, an upper portion on the adapter member for allowing the member to be attachable beneath a firearm, and a lower portion pivotally attached to the adapter member, the lower portion for supporting another component thereon, wherein the other component can move between a vertical downward position for to a folded position adjacent to the firearm.
The another component can include a light. The another component can include a vertical fore grip. The another component can include both a vertical fore grip and a light. The another component can include a vertical fore grip with a light integrated inside of the fore grip.
A novel method of attaching a foldable accessory mounting plate to a firearm, can include the steps of providing a firearm having opposite facing picatinny rails underneath the firearm, providing a top plate member with an upper surface having a pair of opposite facing grooves, providing a bottom plate member with opposite facing picatinny rails, hingedly attaching one end of the bottom plate member to the top plate member by the hinge, sliding and mating the opposite facing grooves on the upper surface of the top plate member about the picatinny rails underneath the firearm, providing a vertically extending elongated accessory having an upper surface having a pair of opposite facing grooves, sliding and mating the opposite facing grooves on the upper surface of the elongated accessory about the picatinny rails on the bottom plate member, and folding the vertically extending elongated accessory to a horizontal orientation underneath the firearm by the hinge between the top and the bottom plate member.
The accessory can include a light. The accessory can include vertical fore grip. The method can include the steps of deploying a pair of legs with feet beneath the vertical fore grip and expanding the feet on the legs apart from one another. The vertical fore grip can include a light.
Another embodiment of the invention can have telescoping extendable legs that can be individually extended from beneath the fore grip handle.
The invention can be used with fore grips having concealable and collapsible bipod legs. Alternatively, the accessory mount can be used with other types of fore grips such as basic vertical fore grips, or any stands that can be attached to rails such as picatinny rails beneath firearms.
A firearm fore grip with accessory mount holder, can include an elongated handle having a top end and a bottom end and outer sidewalls between the top end and the bottom end, and an accessory mount having a portion that is attached to a portion of the outer sidewalls of the handle, the accessory mount having rails for allowing an accessory to be removably attached to the rails on the accessory mount.
The accessory mount can be molded to a side portion of the outer sidewalls of the handle.
Another embodiment of the firearm adapter can include an adapter member having an upper side and a lower side, a clamp on the upper side of the adapter member for allowing the member to be clamped to picatinny rails located beneath a firearm, a swing plate pivotally attached to the lower side of the adapter member, the swing plate having picatinny side edges for supporting an accessory thereon, and a sliding switch for allowing the swing plate to be released from a horizontal locked position to be able to rotate to a substantially vertical position.
The sliding switch can include an angled raised surface for allowing a finger of a user to push against, and a spring for biasing the sliding switch to the locked position. The sliding switch can include a set screw for adjusting the biasing extension of the spring.
The adapter can include a catch on a free end of the swinging plate for catching onto a protruding end on the sliding switch, so that the swinging plate is held in the locked position, and a spring loaded latch for locking the swinging plate in the substantially vertical position.
The adapter can include both a first spring for biasing the sliding switch to the locked horizontal position, and a second spring for locking the swinging plate to the substantially vertical position.
The accessory supported by the adapter can be a vertical fore grip, a bipod, or a fore grip with collapsible bipod legs. Additionally, the accessory can include a light or laser source.
A novel method of attaching a foldable accessory mounting plate to a firearm, can include the steps of providing a firearm having opposite facing picatinny rails underneath the firearm, clamping upper sides of a top plate member about the picatinny rails, pivotally attaching one end of a bottom plate member to the top plate member, locking the bottom plate member into a folded horizontal position parallel to the top plate member by a sliding switch being moved in one direction, and releasing the bottom plate member to rotate to a substantially vertical position by moving the sliding switch in an opposite direction.
The method can include the steps of spring biasing the sliding switch toward the one position, and/or locking the bottom plate member to the substantially vertical position by a spring.
A folding rail for firearms can be a folding rail assembly that can be substituted for an existing picatinny rails on a firearm, The folding rail can include a plate shaped member having a first end, a second end, a first longitudinal picatinny rail along one side of the plate shaped member between the first end and the second end, and a second longitudinal picatinny rail along an opposite side of the plate shaped member between the first end and the second end, and a hinge for allowing a portion of both the first longitudinal picatinny rail and the second picatinny rail to pivot relative to the plate shaped member, from a horizontal position to a substantially vertical position, wherein the plate shaped member is attached to an undersurface of a firearm.
The folding rail can include a latch for locking the portion of both the first longitudinal picatinny rail and the second picatinny rail to be in the horizontal position relative to the plate shaped member, and mounting holes in the plate shaped member for allowing fasteners to attach the plate shaped member to the undersurface of the firearm.
The plate shaped member can include a forward end with picatinny rails on both sides, and a rearward end with picatinny rails on both sides, with a middle rail section between the foreward end and the rearward end, the middle end being pivotally attached to one of the foreward end or the rearward end. The pivotal middle rail section includes picatinny rails on both sides of the middle rail section.
Further objects and advantages of this invention will be apparent from the following detailed description of a presently preferred embodiment, which is illustrated in the accompanying flow charts and drawings.
BRIEF DESCRIPTION OF THE FIGURES
Referring particularly to the drawings for the purposes of illustration only, and not limitation:
FIG. 1 is a bottom rear right perspective view of a folding stacking unit.
FIG. 2 is a bottom front left perspective view of the stacking unit of FIG. 1 .
FIG. 3 is a top rear right perspective view of the stacking unit of FIG. 1 .
FIG. 4 is top front left perspective view of the stacking unit of FIG. 1 .
FIG. 5 is a rear end view of the stacking unit of FIG. 1 .
FIG. 6 is a left side view of the stacking unit of FIG. 1 .
FIG. 7 is a front end view of the stacking unit of FIG. 1 .
FIG. 8 is a top view of the stacking unit of FIG. 1 .
FIG. 9 is a bottom view of the stacking unit of FIG. 1 .
FIG. 10 is an exploded perspective view of the stacking unit of FIG. 1 .
FIG. 11 is an exploded perspective view of the stacking unit of FIG. 1 .
FIG. 12 is an enlarged rear end view of the stacking unit of FIGS. 1 , 5 .
FIG. 13 is an enlarged left side view of the stacking unit of FIGS. 1 , 6 .
FIG. 14 is a cross-sectional view of the stacking unit of FIG. 12 along arrows 14 X.
FIG. 15 is a rear view of the preceding stacking unit with pivot rail folded forward.
FIG. 16 is a left side view of FIG. 15 .
FIG. 17 is a cross-sectional view of FIG. 15 with pivot rail folded forward.
FIG. 17A is an enlarged view of the rail mount plate, release button, pivot rail latch, release button finger access slot and latch spring shown in FIG. 17 .
FIG. 18 is another cross-section view of FIGS. 15 , 17 with pivot rail being folded.
FIG. 18A is an enlarged view of the rail mount plate, release button, pivot rail latch, release button finger access slot and latch spring shown in FIG. 18 .
FIG. 19 is another cross-section view of FIGS. 15 , 18 - 18 with pivot rail locked.
FIG. 19A is an enlarged view of the rail mount plate, release button, pivot rail latch, release button finger access slot and latch spring shown in FIG. 19 .
FIG. 20 is a rear bottom right perspective view of the folding stacking unit attached to a vertical fore grip, with the stacking unit mounted to a picatinny rail of a firearm.
FIG. 21 is a front bottom left perspective view of FIG. 20 showing the folding stacking unit attached to a vertical fore grip, with the stacking unit mounted to the firearm.
FIG. 22 is a rear top right perspective view of the folding stacking unit attached to fore grip, with the stacking unit mounted to a picatinny rail of a firearm of FIG. 20 .
FIG. 23 is front top left perspective view of the folding stacking unit attached to a vertical fore grip, with the stacking unit mounted to the firearm of FIG. 21 .
FIG. 24 is side view of bipod vertical fore grip detached from the stacking unit that is mounted beneath the firearm.
FIG. 25 is another side view of FIG. 24 with the fore grip mounted to the stacking unit.
FIG. 25A is an enlarged view of the fore grip mounted to stacking unit of FIG. 25 .
FIG. 26 is another view of FIGS. 24-25 with fore grip in folded position to firearm.
FIG. 26A is an enlarged view of the folded fore grip and mounting plate of FIG. 26 .
FIG. 27 is a side view of a foldable light/foldable fore grip with light detached from a stacking unit that is mounted beneath a firearm.
FIG. 28 is another view of FIG. 27 showing the light/fore grip with light, attached to the firearm mounted stacking unit, with light/fore grip with light, in folded position.
FIG. 29 is another view of FIGS. 27-28 with light/fore grip with light in downward extended position, with the light being useable as a map light, or the light being used as a vertical fore grip.
FIG. 30 shows a novel combined vertical fore grip with built in-light.
FIG. 31 is a side cross-sectional view of the interior of the fore grip light of FIG. 30 .
FIG. 32 is a front bottom perspective view of another embodiment of the folding stack adapter assembly with long clamp.
FIG. 33 is a rear bottom perspective view of the adapter assembly of FIG. 32 .
FIG. 34 is a front top perspective view of the adapter assembly of FIG. 32 .
FIG. 35 is a rear top perspective view of the adapter assembly of FIG. 32 .
FIG. 36 is a top view of the folding stack adapter assembly of FIG. 32 .
FIG. 37 is a side view of the folding stack adapter assembly of FIG. 32 .
FIG. 38 is a bottom view of the adapter assembly of FIG. 32 .
FIG. 39A is a left view of the adapter assembly of FIG. 32 .
FIG. 39B is an enlarged view of a portion of the adapter assembly of FIG. 39A showing radial slot cut in clamping apex to relieve mechanical clamping stress.
FIG. 39C is another radial slot cut in clamping apex to relieve mechanical clamping stress.
FIG. 40 is a right view of the adapter assembly of FIG. 32 .
FIG. 41 is a front top perspective view of the adapter assembly of FIG. 32 with a long clamp.
FIG. 42 is a front top perspective view of the adapter assembly of FIG. 32 with exploded long clamp.
FIG. 43 is a front top perspective view of adapter assembly with two short clamps.
FIG. 44 is a front top perspective view of the adapter assembly of FIG. 32 with exploded short clamps.
FIG. 45 is an exploded top front perspective view of the adapter assembly with long clamp.
FIG. 46 is an exploded top rear perspective view of the adapter assembly of FIG. 45 with long clamp.
FIG. 47 is an exploded bottom front perspective view of the adapter assembly of FIG. 45 with long clamp.
FIG. 48 is an exploded bottom rear perspective view of the adapter assembly of FIG. 45 with long clamp.
FIG. 49 is an end view of the adapter assembly of FIG. 45 with long clamp.
FIG. 49A is a cross-sectional view of the adapter assembly of FIG. 45 with pivot rail up.
FIG. 49B is an enlarged view of the thumb slide of FIG. 49A .
FIG. 49C is an enlarged view of the detent latch of FIG. 49B .
FIG. 50 is a side view of the adapter assembly.
FIG. 51 is a side view of the adapter assembly with swing plate down.
FIG. 51A is a cross-section view of the adapter assembly of FIG. 49A with pivot rail down.
FIG. 51B is another view of the thumb slide of FIG. 49B with pivot rail down.
FIG. 51C is another view of the detent latch of FIG. 49C with pivot rail down.
FIG. 52 is a side view w/pivot rail down.
FIG. 53 is a bottom front perspective view of the adapter assembly of the preceding figures with picatinny rail and foregrip with collapsible bipod legs.
FIG. 54 is a bottom rear perspective view of the adapter assembly with picatinny rail and foregrip with collapsible bipod legs of FIG. 53 .
FIG. 55 is a front top perspective view of the adapter assembly with picatinny rail and foregrip with collapsible bipod legs of FIG. 53 .
FIG. 56 is a front rear perspective view of the adapter assembly with picatinny rail and foregrip with collapsible bipod legs of FIG. 53 .
FIG. 57 shows the adapter assembly of the preceding figures locked to a gun's picatinny rail separated from foregrip with collapsible bipod legs.
FIG. 58 shows the adapter assembly locked to the gun's picatinny rail of FIG. 57 for foregrip with collapsible legs.
FIG. 59 is another view of the adapter assembly swinging open on an unlatched pivot rail.
FIG. 60 is a bottom front perspective view of a folding rail assembly.
FIG. 61 is a bottom rear perspective view of the folding rail assembly of FIG. 60 with pivot rail down.
FIG. 62 is a top rear perspective view of the folding rail assembly of FIG. 61 with pivot rail down.
FIG. 63 is another top front perspective view of the folding rail assembly of FIG. 62 with pivot rail down.
FIG. 64 is a top view of the folding rail assembly of FIG. 60 .
FIG. 65 is a left view of the folding rail assembly of FIG. 60 .
FIG. 66 is a front view of the folding rail assembly of FIG. 60 .
FIG. 67 is a right view of the folding rail assembly of FIG. 60 .
FIG. 68 is a bottom view of the folding rail assembly of FIG. 60 .
FIG. 69 shows a folding rail assembly being used to replace stock picatinny rail supplied with a gun, and detached foreward grip with collapsible bipod legs.
FIG. 70 is another view of FIG. 69 with foreward grip having collapsible bipod legs connected to a locked folding rail assembly on gun.
FIG. 71 is another view of FIG. 70 with foreward grip having collapsible bipod legs attached to the folding rail assembly swinging open on unlatched pivot rail.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
The invention claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/905,556 filed Mar. 7, 2007, and this invention is a continuation in part of U.S. patent application Ser. No. 11/485,762 filed Jul. 13, 2006, which is a continuation in part of U.S. patent application Ser. No. 10/725,082 filed Dec. 2, 2003, now U.S. Pat. No. 7,111,424, and U.S. Design patent application Ser. No. 29/259,347 filed May 5, 2006, all by the same inventors and assigned to the same assignee, which are all incorporated by reference.
The inventors of the subject invention have to date patented at least one U.S. Pat. No. 7,111,424 to Gaddini, which is incorporated by reference. This patent includes a replaceable mounting assembly that allows for mounting of the gun handle by various means to a gun. A fore grip or gun handle, designed with ergonomic reasons in mind, provides a stable means of holding the gun. A plurality of legs that are concealed within the fore grip are coupled via a hinge to a spring piston assembly. A spring-loaded fulcrum release mechanism holds the piston assembly in a compressed and locked position.
When the piston assembly is released upon activation of the spring-loaded fulcrum release mechanism, the legs are driven downwards by the piston and upon being released from the confinement of the fore grip are deployed outwards to a locked position by a hinge or pivot mechanism. The legs have feet that are designed so that, when the legs are concealed within the handle, the feet seal off the deployment and spreader mechanisms from entrance of any debris, material etc that may interfere with the deployment of the bipod.
As shown in the figures, the invention can be used with the inventors novel fore grip that has a mounting section or end having parallel rails that can be attached to rails, such as picatinny rails on a firearm such as a rifle, and the like, by adjusting the head piece clamps with rail clamp bolt. The fore grip can include of a machining or a casting that utilizes aluminum or a molding that utilizes high impact resistant polymer or a composite material. The fore grip is a grip for gripping by the hand of a user when the fore grip is attached to the firearm.
Although the mounting end is shown as being an integral part of the handle for illustration purposes only, it should be understood that the mounting end head piece can be a separate component that is then attached by other members, such as threads or a lock screw or locking bolt to the handle. For illustrative purposes, the mounting end head piece uses a picatinny mounting rail (MIL-STD-1913 rail), a mounting system widely used by military for attachment of various devices to military rifles. However, it should be understood that other methods of attachment to a firearm could be used.
As described in the parent patent applications that are incorporated by reference, the fore grip can have a handle portion, with bottom retaining cap have a concealable and collapsible bipod legs. One version can have a tubular recess consisting of a first cylindrical cutout housing the bipod legs when concealed and a sliding piston that deploys the legs and a second cylindrical cutout housing a release mechanism and a void space for other accessories. The release mechanism such as a depressible button has a compression spring positioned between the piston assembly and the bottom of the first cylindrical cutout and the compression spring. The legs are connected to the bottom of the piston assembly via a hinge and spring that when released from confinement within the fore grip, causes the legs to expand outward until deployed.
Another version of the fore grip with bipod uses only one spring, wherein the legs can be gravity and/or snap/shook released from the handle by a switch(such as the depressible button) and the spring expands the legs out to the fully deployed position.
To use the fore grip, a user simply attaches the fore grip to the firearm, regardless of whether or not the bipod legs are deployed. If the legs are deployed, then the user has the option of using the gun with the legs deployed or compressing or squeezing the legs together, and pushing them upwards into the fore grip until the male part of the spring-loaded fulcrum release mechanism catches and locks the bipod legs and the piston assembly into the closed position.
As described above, the invention can be used with the inventors' novel bipod fore grip shown in the figures. A preferred embodiment can have the head piece having a length of approximately 1.85 inches a width of approximately 1.29 inches and a height of approximately 1.15 inches. In a fully leg retracted/closed position, the fore grip can have a height of approximately 6.32 inches. The handle portion 110 can have a length of approximately 2.95 inches and a width of approximately 1.37 inches. The legs can have a width of approximately 0.73 inches along with the feet having a width of approximately 0.99 inches. In a fully deployed/expanded position, the fore grip can have an overall height of approximately 8.57 inches, with the legs 120 having a spread eagle angle therebetween of approximately 76 degrees, and the inside angle of the feet 128 to the rest of the legs being approximately 52 degrees. The feet can be spread apart from toe to toe at approximately 6.95 inches.
Although, the preferred embodiment lists specific dimensions, the invention can be practiced with different sized and shaped components.
The fore grip can be made from various components such as but not limited to polymeric materials, such as but not limited to plastic and/or glass filled nylon with and without metal inserts such as aluminum, galvanized metal, stainless steel, and the like Additionally, the fore grip can include void spaces where possible to decrease weight.
Although a depressible button is shown above, the invention can use other types of activation such as but not limited to toggle switches, pressure actuated switches, temperature actuated switches and the like, to release the inside legs to slide down and expand outward from beneath the housing.
FOLDING STACKING PLATE DESIGNATOR REFERENCE NUMBERS
1000 Folding Stacking Unit
1004 Optional clamp turn screws to attach clamps
1006 Optional side plate for clamp turn screws
1010 Rail Mount Plate/top plate member
1012 leg member
1013 inwardly facing groove
1014 leg member
1015 inwardly facing groove
1018 notch on lower surface of top plate member
1019 pin-hole
1020 Pivot Rail Member/lower-bottom plate member
1022 Upper pivot rail edge
1024 Side Rail
1026 Side Rail
1028 front tab
1029 pin-hole
1030 Pivot Pin
1040 Release Button
1045 fastener(screw, and the like)
1050 Pivot Rail Latch
1052 Ledge edge of Latch
1055 Longitudinal Top Slot
1060 Release Button
1062 Finger Access Slot of Release button
1070 Latch Cover Plate
1074 Downwardly protruding pin
1075 fastener(s)
1075 R threaded receiving holes
1080 Picatinny Rail
1090 Vertical Fore Grip
1100 Latch Spring
1110 Latch Catch
1200 Firearm(i.e. rifle, etc.)
1400 Attachable/detachable light accessory/fore grip with light
1450 upper mounting plate with grooves
1455 fastening screw knob
1500 fore grip with built in light
1510 lens
1515 light source
1520 cap
1530 batteries
1550 inside of light fore grip
1590 depressible switch
1700 ) Adapter assembly with one long clamp.
1710 ) Adapter body.
1720 ) Swing plate.
1730 ) Pivot pin.
1740 ) Detent plate.
1750 ) Detent latch.
1760 ) Picatinny rail.
1770 ) Grip pod assembly.
1780 ) Adapter assembly with two short clamps.
1790 ) Gun.
1800 ) Folding rail assembly.
1810 ) Folding assembly swing plate.
1820 ) Thumb nut.
1830 ) Thumb slide.
1840 ) Plate latch.
1850 ) Long clamp.
1860 ) Set screw.
1870 ) Clamp screw.
1880 ) Short clamp A.
1890 ) Short clamp B.
1900 ) Radial stress relief slot.
1910 ) Slide spring.
1920 ) Detent spring.
1930 ) Folding rail body.
1940 ) Folding rail swing plate latch.
FIG. 1 is a bottom rear right perspective view of a folding stacking unit 1000 . FIG. 2 is a bottom front left perspective view of the stacking unit 1000 of FIG. 1 . FIG. 3 is a top rear right perspective view of the stacking unit 1000 of FIG. 1 . FIG. 4 is top front left perspective view of the stacking unit 1000 of FIG. 1 . FIG. 5 is a rear end view of the stacking unit 1000 of FIG. 1 . FIG. 6 is a left side view of the stacking unit 1000 of FIG. 1 . FIG. 7 is a front end view of the stacking unit 1000 of FIG. 1 . FIG. 8 is a top view of the stacking unit 1000 of FIG. 1 . FIG. 9 is a bottom view of the stacking unit 1000 of FIG. 1 .
Referring to FIGS. 1-10 , stacking unit 1000 can have a rail mount plate 1010 being a top plate member which hingedly attaches to a lower plate member 1020 which functions as a lower plate member by pivot pin 1030 . FIG. 10 is an exploded perspective view of the stacking unit 1000 of FIG. 1 . FIG. 11 is an exploded perspective view of the stacking unit 1000 of FIG. 1 .
Referring to FIGS. 1-11 , the stacking unit 1000 can include an upper surface with a pair of leg members 1012 , 1014 each with internal facing side grooves 1013 , 1015 . The grooves 1013 , 1015 are inwardly facing clamp edges that can slide about existing picatinny rails underneath of a firearm, such as a rifle and the like, which will be described in greater detail below. The inwardly facing clamp edges 1013 , 1015 can also include optional clamp turn screws 1004 ( FIG. 20 ) to attach the inwardly facing clamp edges about both sides of the existing picatinny rails underneath the firearm.
The stacking unit 1000 can also include a lower plate member 1020 (pivot rail) having opposite facing side rails 1024 , 1026 that can be similar to or replicate the existing picatinny rails underneath the firearm. The side rails 1024 , 1026 can be used for mounting a vertical fore grip such as the inventor's novel bipod fore grip thereon, which is shown below in FIG. 20 .
The lower member 1020 of the stacking unit 1000 can be pivotally mounted to the rail mount plate 1010 by a pivot pin 1030 that passes through pin-hole 1029 of the bottom plate member 1020 and pin-hole 1019 of top plate member 1010 . The fit can be a frictional fit where the operator pulling back on front tab 1028 can extend the pivot rail member(lower member) from a position horizontal to and within the top member(rail plate member) 1010 to a position substantially perpendicular to the rail mount plate member 1010 , where it is held in place by friction. Tab 1028 rests inside of notch 1018 on the lower surface of top plate member 1010 while lower plate member 1020 is perpendicular to top plate member 1010 .
FIG. 12 is an enlarged rear end view of the stacking unit 1000 of FIGS. 1 , 5 . FIG. 13 is an enlarged left side view of the stacking unit 1000 of FIGS. 1 , 6 . FIG. 14 is a cross-sectional view of the stacking unit 1000 of FIG. 12 along arrows 14 X.
FIG. 15 is a rear view of the preceding stacking unit 1000 with lower plate member 1020 (pivot rail member) folded forward. FIG. 16 is a left side view of FIG. 15 .
FIG. 17 is a cross-sectional view of FIG. 15 with pivot rail member 1020 folded forward. FIG. 17A is an enlarged view of the rail mount plate(top plate member) 1010 , release button 1060 , pivot rail latch 1050 , release button finger access slot 1060 and latch spring shown 1100 in FIG. 17 .
FIG. 18 is another cross-section view of FIGS. 15 , 17 with pivot rail member(lower plate member 1020 ) being folded. FIG. 18A is an enlarged view of the rail mount plate member(top plate member) 1010 , release button 1060 , pivot rail latch 1050 , release button finger access slot 1060 and latch spring 1100 shown in FIG. 18 .
FIG. 19 is another cross-section view of FIGS. 15 , 18 - 18 with pivot rail locked. FIG. 19A is an enlarged view of the rail mount plate, release button 1060 , pivot rail latch 1050 , release button finger access slot 1060 and latch spring 1100 shown in FIG. 19 .
Referring to FIGS. 12-18B , pushing the lower plate member(pivot rail member) 1020 in the opposite direction of CL allows the lower member 1020 to pivot back to latch and lock onto the rail mount plate 1010 which is shown in FIGS. 12-18B below.
As shown in FIGS. 10-11 , and 17 - 19 A, latch spring 1100 fits inside a top longitudinal slot 1055 within latch 1050 . An inner end of latch 1050 includes a ledge edge 1052 which can latch against upper ledge edge 1022 of pivot rail member 1020 (shown more clearly in FIGS. 17-19A . A release button 1040 can be held in place by a fastener 1045 such as a screw, and the like, which fastens into threaded surfaces in the end of pivot rail latch 1050 opposite to end having ledge edge 1052 .
A downwardly protruding pin 1074 in plate 1076 can fit into longitudinal top slot 1055 of pivot rail latch 1050 and be held in place by fasteners 1075 , such as screws which lock plate 1070 to threaded receiving holes 1075 R in top plate member 1010 .
The downwardly protruding pin 1074 is useful so that pivot rail latch 1050 can move to the left and right by the slot 1055 sliding about the downwardly protruding pin 1074 .
The operation of using the release button 1060 will know be described in reference to FIGS. 19A , 18 A, and 17 A in that order, the release button 1060 can be moved by the operator using a finger inserted into access slot 1062 of the release button 1060 to press against downwardly protruding lip edge 1042 in the direction of arrow R. Mount plate 1010 which is fixably attached to pivot rail latch 1050 contracts against latch spring 1100 while moving ledge edge 1052 away from upper pivot rail edge 1022 of pivot rail member 1020 . This allows the pivot rail member(lower plate member 1020 ) to be able to pivot downward to a vertical position as shown in FIG. 17 .
The pivotable lower plate member 1020 can have a pair of opposite facing rails that can mount to the inventors' bipod with extendable legs, which is shown and described in their previous patent, and other patents pending.
Alternatively, the stacking unit 1000 can allow for other fore grips to be mounted thereon. Still furthermore, the stacking unit can be an integral part of a vertical fore grip.
While a pullout type switch is shown, the lower portion of the stacking unit can be released with other types of buttons, such as a depressible button, and the like.
FIG. 20 is a rear bottom right perspective view of the folding stacking unit 1000 attached to a vertical fore grip 1090 , with the stacking unit 1000 mounted to a picatinny rail 1080 of a firearm(not shown) such as a rifle, and the like. As previously described the clamp screw 1004 can be used to attach the folding stacking unit 1000 by holding an optional side plate 1006 in place.
FIG. 21 is a front bottom left perspective view of FIG. 20 showing the folding stacking unit 1000 attached to a vertical fore grip 1090 , with the stacking unit 1000 mounted to the picatinny rails 1080 of a firearm(not shown) such as a rifle, and the like. FIG. 22 is a rear top right perspective view of the folding stacking unit 1000 attached to fore grip 1090 , with the stacking unit 1000 is mounted to a picatinny rail 1080 of a firearm of FIG. 20 . FIG. 23 is front top left perspective view of the folding stacking unit 1000 attached to a vertical fore grip 1090 , with the stacking unit 1000 mounted to the firearm of FIG. 21 .
FIG. 24 is side view of bipod vertical fore grip 1090 detached from the stacking unit 1000 that is mounted beneath the firearm 1200 . As previously described, the clamping grooves of the stacking unit 1000 can mateably slide about the picatinny type rails 1080 under the firearm 1200 . Alternatively, the stacking unit 1000 can be attached to the picatinny rails by removing the optional side plate 1006 (shown in FIG. 20 ), by fasteners 1004 and positioning the remaining clamping groove about a picatinny rail and fastening the side plate 1006 back in place with fastener 1004 .
FIG. 25 is another side view of FIG. 24 with the fore grip 1090 mounted to the stacking unit 1000 . FIG. 25A is an enlarged view of the fore grip 1090 mounted to stacking unit 1000 of FIG. 25 .
FIG. 26 is another view of FIGS. 24-25 with fore grip in folded position to the firearm. FIG. 26A is an enlarged view of the folded fore grip 1090 and mounting plate 1000 with firearm 1200 of FIG. 26 .
Similar to the techniques for mounting the stacking unit 1000 to the firearm 1200 , the fore grip 1090 can be mounted by sliding the grooves on the top of the fore grip 1090 about the side rails 1024 , 1026 on the sides of the lower plate member(pivot rail member) 1020 . Alternatively, the side plates on the top of the fore grip 1090 can be removed and the fore grip 1090 attached to the side rails of the pivot rail member 1020 similar to the technique described above.
Referring to FIGS. 25 , 25 A, 26 and 26 A, pivot rail member 1020 with fore grip 1090 can be held in a horizontal orientation by a frictional fit. Alternatively, a pivotal lock catch 1120 which is pivotally attached to an undersurface portion of top plate member 1010 to one side of the fore grip 1090 has a pivotal arm with a notch end 1022 . Folding up fore grip 1090 in the direction of arrow F causes pivotal lock catch 1120 to rotate up so that rounded tip edges about notch 1022 push back spring biases spring pin 1135 in set screw 1130 until pin 1135 extends and catches into notch 1022 resulting in the fore grip 1090 being locked in a horizontal position. Pulling down on the bottom of fore grip 1090 can cause the other tip edge of pivotal lock catch 1120 to push against pin 1135 allowing the fore grip 1090 to go back to a vertical position.
LIGHT EMBODIMENTS
FIG. 27 is a side view of a foldable light/foldable fore grip light 1400 detached from a stacking unit 1000 that is mounted beneath a firearm 1200 . FIG. 28 is another view of FIG. 27 showing the light/fore grip 1400 with light 1410 , attached to the firearm mounted stacking unit 1000 , with light/fore grip 1400 with light 1410 , in folded position. FIG. 29 is another view of FIGS. 27-28 with light/fore grip 1400 with light 1410 in downward extended position, with the light 1410 being useable as a map light, or the light being used as a vertical fore grip.
Referring to FIGS. 27-29 , the invention can have a novel light mounted to the stacking unit 1000 , so that the light can be used in either a folded position, or in a downwardly extending position. The light/fore grip 1400 with light 1410 can have an upper plate member assembly 1450 similar to dual inwardly facing grooves that exist on the top of the fore grip 1090 described above, with optional fastener 1455 , which can attach to the lower plate member 1120 similar to the previous embodiments above.
The folding unit can also allow the light to fold frontward, so that the light is turned on in the direction of where the firearm is pointed. Additionally, the folding unit can allow the light to face rearward behind the firearm. Additionally, the folding unit can allow the light to face sideways to the left and to the right of the firearm, as well.
Still furthermore, the invention can allow for both a vertical fore grip with a light built 1550 into the fore grip 1500 , so that it can have dual functions for use as a vertical fore grip and as light. The light can be useful for non firearm use, such as a map light to allow the operator to view maps, and the like, during dark conditions. FIG. 30 shows a novel combined vertical fore grip 1500 with built in-light. FIG. 31 is a side cross-sectional view of the interior of the fore grip light 1500 of FIG. 30 .
Referring to FIGS. 30-31 the fore grip 1500 can have a similar shape to the exterior surfaces of the fore grip 1090 previously described with an upper end 1505 being attachable to the lower plate member 1020 of stacking unit 1000 similar to the fore grip 1090 previously described. The inside 1550 of the fore grip 1500 can include components such as but not limited to batteries 1530 and a light source 1515 , such as a bulb, LED(light emitting diode), and the like, and lens 1510 . Cap 1520 can rotate to both turn on the light and allow the lens 1510 to extend beneath fore grip 1500 . Alternatively, side button 1590 can be depressed to active and deactivate light 1515 .
A list of components for additional embodiments will now be described. 1700 ) Adapter assembly with one long clamp.
1710 Adapter body. 1712 Front end 1713 Front horizontal slot 1715 Rear horizontal slot 1717 Longitudinal slot
1718 Rear end
1719 Cavity with mateable grooved interior walls 1720 Swing plate. 1722 . Side edges 1724 bottom of plate with raised flat ribs(four shown) 1725 hinge end 1726 top of plate with raised rounded ribs(two shown) 1727 groove in rounded surface of hinge end 1725 1728 outer ledge catch end 1730 Pivot pin. 1740 Detent plate. 1745 Screw type fasteners 1750 Detent latch. 1752 U-shaped slot 1758 Protruding end 1760 Picatinny rail. 1770 Grip pod assembly. 1780 Adapter assembly with two short clamps. 1790 Gun. 1800 Folding rail assembly. 1810 Folding assembly swing plate. 1815 . Hinge 1820 Thumb nuts. 1830 Thumb slide. 1835 Screw type fastener 1840 Plate latch. 1842 Raise side edges of plate latch 1844 Rear end of latch 1845 . Slot in latch 1848 Protruding end 1850 Long clamp. 1860 Set screw. 1870 Clamp screws. 1875 Threaded ends. 1880 Short clamp A. 1890 Short clamp B. 1900 Radial stress relief slot. 1910 Slide spring. 1920 Detent spring. 1930 Folding rail body. 1932 . Forward End 1933 . opening 1935 . Base 1937 . opening 1938 rearward end 1940 Folding rail swing plate latch. 1942 . Rotatable Knob 1945 Protruding edge
Adapter Assembly with One Long Clamp
FIG. 32 is a front bottom perspective view of another embodiment of the folding stack adapter assembly 1700 with long clamp. FIG. 33 is a rear bottom perspective view of the adapter assembly 1700 of FIG. 32 . FIG. 34 is a front top perspective view of the adapter assembly of FIG. 32 . FIG. 35 is a rear top perspective view of the adapter assembly 1700 of FIG. 32 . FIG. 36 is a top view of the folding stack adapter assembly 1700 of FIG. 32 . FIG. 37 is a side view of the folding stack adapter assembly 1700 of FIG. 32 . FIG. 38 is a bottom view of the adapter assembly 1700 of FIG. 32 . FIG. 39A is a left view of the adapter assembly 1700 of FIG. 32 . FIG. 39B is an enlarged view of a portion of the adapter assembly 1700 of FIG. 39A showing radial slot cut in clamping apex to relieve mechanical clamping stress. FIG. 39C is another radial slot cut in clamping apex to relieve mechanical clamping stress. FIG. 40 is a right view of the adapter assembly 1700 of FIG. 32 . FIG. 41 is a front top perspective view of the adapter assembly 1700 of FIG. 32 with a long clamp 1850 . FIG. 42 is a front top perspective view of the adapter assembly 1700 of FIG. 32 with exploded long clamp 1850 .
FIG. 45 is an exploded top front perspective view of the adapter assembly with long clamp. FIG. 46 is an exploded top rear perspective view of the adapter assembly of FIG. 45 with long clamp. FIG. 47 is an exploded bottom front perspective view of the adapter assembly of FIG. 45 with long clamp. FIG. 48 is an exploded bottom rear perspective view of the adapter assembly of FIG. 45 with long clamp 1850 . FIG. 49 is an end view of the adapter assembly of FIG. 45 with long clamp 1850 . FIG. 49A is a cross-sectional view of the adapter assembly of FIG. 45 with pivot rail up.
FIG. 49B is an enlarged view of the thumb slide of FIG. 49A . FIG. 49C is an enlarged view of the detent latch of FIG. 49B . FIG. 50 is a side view of the adapter assembly. FIG. 51 is a side view of the adapter assembly with swing plate down. FIG. 51A is a cross-section view of the adapter assembly of FIG. 49A with pivot rail down. FIG. 51B is another view of the thumb slide of FIG. 49B with pivot rail down. FIG. 51C is another view of the detent latch of FIG. 49C with pivot rail plate 1720 down. FIG. 52 is a side view w/pivot rail plate 1720 down.
Referring to FIGS. 32-52 , an adapter assembly with one long clamp 1700 can include a rectangular adapter body 1710 having a plate type configuration. Located on the bottom the adapter assembly body 1710 can be swing plate 1720 with side edges 1722 similar to the edges of a picatinny rails(shown as 1760 in FIG. 53 ) that are often attached underneath of a weapon. The pivoting plate 1720 can be located between the front end 1712 and rear end 1718 of the adapter body 1710 . The plate 1720 can have a bottom side 1724 with raised flat ribs, and an upper top side 1726 with raised rounded ribs. One end 1725 of the plate 1720 can be pivotally attached by a pivot pin 1730 to a front end 1712 of the adapter body 1710 (see FIG. 51A ).
Detent Plate in Front End
In the front end 1712 of the adapter body 1710 can be detente plate 1740 which holds a detent spring 1920 on inner side. See for example, FIGS. 32 , 34 , 39 A, 41 - 45 , 47 , 48 , 49 C, 51 C. The detent plate 1740 can be a fixably attached to the front end 1712 of the adapter body 1710 by screw type fasteners 1745 . The detent spring 1920 pushes into a U-shaped slot 1752 of the detent latch 1750 . The opposite protruding end 1758 is biased toward and against the pivot hinge 1725 . The rounded exterior surface of the pivot hinge 1725 allows for the rail plate 1720 to easily rotate downward until the protruding end 1758 locks into groove 1727 in the exterior surface 1725 of the swing plate 1720 so that the pivoting plate 1720 is locked in a substantially vertical orientation relative to the adapter body 1710 . (See FIGS. 49A , 49 C, 51 A, 51 C).
To rotate the pivoting plate 1720 back to a horizontal position, the user can press against the pivoting plate, often by grabbing the accessory clamped to the plate such as the foregrip to overcome the spring tension 1920 of the detent plate 1740 .
Thumb Slide in Rear End
In the rear end 1718 of the adapter body 1710 can be a thumb slide 1830 . See for, example, FIGS. 32 , 33 , 35 , 37 , 38 , 40 , 45 , 46 , 47 , 48 . The thumb slide 1830 can have a raised angled surface and be attached to a slot 1845 in plate latch 1840 by a screw type fastener 1835 (See FIGS. 45 , 47 , 48 ). The plate latch 1840 can have raised side edges 1842 form a dovetail shape that allows the plate latch 1840 to slide within a matching grooves inside of dovetail shaped cavity 1719 in rear end 1718 of the adapter body 1710 . A longitudinal slot 1717 along the longitudinal axis of the rear end 1718 allows for the thumb slide 1830 to slide relative to the rear end 1718 . (See FIGS. 45 , 47 , 48 ).
The freely moving protruding end 1848 of the plate latch 1840 when pushed by the thumb slide 1830 in the direction of arrow X 1 can latch onto and catch the outer ledge catch step-shaped end 1728 of the freely moving end of the swing plate 1720 . The upper surface of the protruding end 1848 can be sloped at an angle so as to lift against the catch step-shaped end 1728 of the swing plate 1720 . The spring 1910 pushes the sloped surface of protruding end 1848 so that it takes up any play between itself and the catch step-shaped end 1728 . This play can exist based due to manufacturing tolerances and/or regular wear of these parts. See for example, FIGS. 49A , 49 B, 51 A, 51 B.
The rear end 1844 of the plate latch 1840 can push against a slide spring 1910 and the length adjustable set screw 1860 so that the protruding end 1848 of the plate latch 1840 is being pushed in the direction of arrow X 1 . The spring is sandwiched between the set screw 1860 and the rear end 1844 of the plate latch 1840 . By not fully seating the screw 1860 against the spring 1910 , the tension of the spring 1910 can be adjusted. Tightening the length adjustable set screw 1860 can further lock the protruding end 1848 of the plate latch against the outer ledge catch end 1728 of the swing plate 1720 . Loosening the set screw 1860 can allow for the thumb slide 1830 to more easily slide in place. The user can release the swing plate 1720 from a horizontal position and rotate in the direction of arrow R, by pushing the thumb slide 1830 in the direction of arrow X 2 , shown in FIGS. 51 , 51 A, 51 B, 52 .
A pair of clamp screws 1870 can pass through horizontal slots ( 1713 in the front end, and horizontal slot 1715 in the rear end 1718 of the adapter body 1710 . See for example, FIGS. 39A , 39 B, 39 C, 40 , 45 - 48 . The threaded ends 1875 of the clamp screws 1870 are held against the long clamp 1850 by respective thumb nuts 1820 . A radial stress relief slot 1900 can be formed between the long clamp 1850 side and the opposite side of the adapter body 1710 . The radial stress relief slot 1900 has interior facing groove side walls that allow for the adapter assembly to wrapped about picatinny rails underneath of a weapon. A user can loosen the thumb nuts 1820 to allow the adapter assembly 1700 to slide about the picatinny rails 1760 underneath a weapon 1790 , such as a gun.
FIG. 53 is a bottom front perspective view of the adapter assembly 1700 of the preceding figures with picatinny rail 1760 and foregrip 1770 with collapsible bipod legs. Such a foregrip with collapsible bipod legs can include ones such as those shown and described in U.S. Pat. Nos. D566,219; 7,111,424; 7,409,791; and 7,490,429 to the same assignees of the subject invention, and which are all incorporated by reference.
FIG. 54 is a bottom rear perspective view of the adapter assembly 1700 attached to a picatinny rail 1760 , where the adapter assembly 1700 is attached to a foregrip 1770 with collapsible bipod legs of FIG. 53 . FIG. 55 is a front top perspective view of the adapter assembly 1700 with picatinny rail 1760 attached to a foregrip 1770 with collapsible bipod legs of FIG. 53 . FIG. 56 is a front rear perspective view of the adapter assembly 1700 attached to picatinny rails 1760 , with the adapter assembly 1700 attached to the upper end of a foregrip 1770 with collapsible bipod legs of FIG. 53 . FIG. 57 shows the adapter assembly 1700 of the preceding figures locked to a gun's picatinny rail 1760 separated from the foregrip 1770 with collapsible bipod legs. FIG. 58 shows the adapter assembly 1700 locked to the gun's picatinny rail 1760 of FIG. 57 with the adapter assembly 1700 attached to the foregrip 1770 with collapsible legs. FIG. 59 is another view of the adapter assembly 1700 with swing plate 1720 swinging open to an unlatched position.
Adapter Assembly with Two Short Clamps
FIG. 43 is a front top perspective view of adapter assembly 1780 with two short clamps 1880 , 1890 . FIG. 44 is a front top perspective view of the adapter assembly 1780 of FIG. 32 with exploded short clamps 1880 , 1890 . Unlike the previous embodiment, the adapter assembly 1780 has two short clamps 1880 , 1890 instead of long clamp 1850 . Other than the short clamps 1880 , 1890 , this embodiment functions similarly to the previous embodiment with long clamp 1850 . A radial stress relief slot 1900 is formed between the pair of short clamps 1880 , 1890 and opposite side of the adapter body 1710 . The two clamps 1880 , 1990 together have less weight and less material and be less costly than a single long clamp 1850 . Reducing weight of the invention can be desirable in the field where soldiers desire the least amount of weight for their equipment. The single long clamp 1850 can be more stable when attaching about picatinny rails underneath of a firearm.
Folding Rail Assembly
FIG. 60 is a bottom front perspective view of a folding rail assembly 1800 . FIG. 61 is a bottom rear perspective view of the folding rail assembly 1800 of FIG. 60 with pivot rail 1810 down. FIG. 62 is a top rear perspective view of the folding rail assembly 1800 of FIG. 61 with pivot rail 1810 down. FIG. 63 is another top front perspective view of the folding rail assembly 1800 of FIG. 62 with pivot rail 1810 down. FIG. 64 is a top view of the folding rail assembly 1800 of FIG. 60 . FIG. 65 is a left view of the folding rail assembly 1800 of FIG. 60 . FIG. 66 is a front view of the folding rail assembly 1800 of FIG. 60 . FIG. 67 is a right view of the folding rail assembly 1800 of FIG. 60 . FIG. 68 is a bottom view of the folding rail assembly 1800 of FIG. 60 .
Referring to FIGS. 60-68 , the folding rail assembly 1800 includes a folding rail body 1930 having a generally planar plate configuration with a foreward end 1932 and a rearward end 1938 , each having openings 1933 , 1937 for allowing fasteners such as screws and bolts to attach the assembly 1800 to an undersurface of a weapon. In a preferred embodiment both the forward end 1932 and the rearward end 1937 have picatinny type side rails on both sides. In the middle of the assembly 1800 between the forward end 1932 and the rearward end 1937 can be pivotal swing plate 1810 also having picatinny type rails on both sides. A hinge 1815 attaches on end of the swing plate 1810 to the forward end 1932 . A swing plate latch 1940 can be on the rearward end 1938 of the rail assembly 1800 . The latch 1940 can be rotatable by a raised knob 1942 that allows for an extended portion 1945 to be over the free end 1812 of the swing plate 1810 .
On the top of the rail assembly 1800 can be a longitudinal base 1935 having a generally flat surface for allowing the rail assembly to sit flush against the undersurface of a firearm.
FIG. 69 shows a folding rail assembly 1800 being used to replace stock picatinny rail that is often supplied with a gun 1790 , and detached foreward grip 1770 with collapsible bipod legs. FIG. 70 is another view of FIG. 69 with foreward grip having collapsible bipod legs connected to a locked folding rail assembly on gun 1790 . FIG. 71 is another view of FIG. 70 with foreward grip 1770 having collapsible bipod legs attached to the folding rail assembly 1800 swinging open on an unlatched pivot rail.
The folding rail assembly 1800 can be a substitute for the picatinny rails that are often attached underneath of firearm. The folding rail assembly can be used underneath the gun or in other areas, such as but not limited to be attached to one side of the gun or on top of the gun.
The folding rail assembly 1800 has a lower profile than the folding stack embodiments that were previously described. The folding rail assembly 1800 would allow for accessories such as a foregrip to be located closer to the weapon, instead of being spaced away from the weapon. A problem with foregrips is that the lower end of a vertical foregrip can extend further than what is desired. For example the lower bottoms of foregrips have been known to catch on the ground, etc., and/or poke into the user.
The folding rail assembly 1800 is more ergonomic than a folding stack assembly since it does not lengthen the overall length of a foregrip that can be attached thereon.
The folding rail assembly 1800 would be similar in weight to an existing picatinny rail system The folding rail assembly 1800 would have substantially less weight and use less material and be less expensive than the folding stack embodiments.
Similar to the previous embodiments, the folding rail can be modified to lock in both the horizontal and vertical positions, using features similar to that of the previous embodiments.
Although the invention mentions a plate, the invention can include different shapes, such as but not limited to oblong shapes, rectangular shapes, cylindrical shapes, and the like.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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Adapter devices, apparatus, systems and methods of allowing a firearm to be supported by a foldable fore grip/gun handle. The fore grip gun handle can have bipod type legs that can be extendable from the handle. The fore grip handle can be just a vertical extension. The adapter can allow for the fore grip/gun handle to move from a fold back position along the bottom of the firearm so that the firearm can be easily carried, and the adapter to can allow for the handle to move down to a vertical support position beneath the firearm when the firearm is to be used. The adapter can also support a light in both a folded position and in a downwardly extended position, where light can be aimed forward, rearward to the side and/or pointed down from the firearm. The adapter can allow for a dual functioning component that can be either or both a fore grip and/or a light source. Other versions of the adapter can include a slidable thumb switch for locking a swinging plate with picatinny side rails to a main plate, and spring loaded detents for locking the swinging plate in substantially vertical orientations. Additionally, a folding rail system can be substituted for the existing picatinny rail system on firearms. The folding rail can have mounting holes for allowing the entire folding rail to be directly attached to the firearm, and have a hinge for allowing portions of the picatinny rails to pivot relative to the rest of the picatinny rails.
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REFERENCE TO RELATED APPLICATIONS
This application is a continuation of our prior patent application Ser. No. 12/462,310, filed Aug. 3, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the carburetor art and more particularly to a carburetor for a liquified petroleum gas, such as propane, powered internal combustion engine for providing a multi-stage pressure reduction of the gas phase of the liquified petroleum gas contained in a liquified petroleum gas storage bottle which contains both the liquid phase and the gas phase of the liquified petroleum gas and metering the amount of the gas for mixing of the gas with ambient air before introduction of the gas/air mixture into the internal combustion engine.
2. Description of the Prior Art
Carburetors of various configurations have heretofore been utilized in connection with providing metered amounts of fuel with air, at either ambient pressure or supercharged, to provide a fuel/air mixture before introducing the fuel/air mixture into, for example, the intake manifold of an internal combustion engine for distribution of the fuel/air mixture to the cylinders of the internal combustion engine. While the advent of direct fuel injection of the fuel into the cylinders of the internal combustion engine has decreased the use of carburetors for many liquid fuel, such as gasoline, powered devices, there are still many applications wherein a carburetor may be economically advantageous utilized.
In gasoline powered internal combustion engines, utilizing a carburetor to mix the gasoline with the air, in general the liquid gasoline is mixed with the air in the carburetor and the liquid gasoline/air mixture flows from the carburetor into an intake manifold of the internal combustion engine. From the intake manifold the liquid gasoline/air mixture is introduced into the individual cylinders of the internal combustion engine. In each cylinder, some or all (depending on the type of engine) of the liquid gasoline is converted into the vapor stage where a spark plug ignites the mixture to provide the power stroke of the piston in the cylinder. The carburetor is generally connected in gas flow communication to the intake manifold so as to be substantially heat isolated from the intake manifold and the internal combustion engine since heating the carburetor might cause the gasoline to convert into the vapor phase in the carburetor which would “vapor lock” the carburetor and prevent the introduction of the desired metered amount of flow of liquid gasoline for mixing with the ambient air.
One present use of carburetors, however, is in the field of gas phase powered internal combustion engines wherein the fuel is the gas phase of a liquified petroleum gas. The containers of the liquified petroleum gas contain both liquid phase and gas phase of the liquified petroleum gas which, for example may be propane. The pressure of the gas phase of the liquified petroleum gas in the container may be on the order of 150 pounds per square inch and, as such, the pressure must be reduced before the metered amount of gas may be mixed with the air to provide the desired mixture of gas/air for introduction into the cylinders of the internal combustion engine. In the prior art a separate pressure regulator has generally been utilized to provide the desired reduction in the gas pressure. However, a separate pressure regulator has often introduced complications in the design of the fuel system for such gas powered internal combustion engines. One such complication is the instance of the liquid being introduced into the regulator. In such instances, generally the liquid phase will convert into the gas phase. In so converting to the gas phase, the regulator will be cooled as the liquid absorbs heat from the structure of the regulator and the performance of the regulator will be erratic. Should such introduction of liquid of the liquid phase into the carburetor continue long enough, there will be no conversion of the liquid phase to the gas phase and the liquid phase of the liquified petroleum gas will remain in the regulator. Since the internal combustion engine is designed to operate on the gas phase, and not the liquid phase, as the fuel in the fuel/air mixture, the engine would cease functioning until the gas phase in the correct metered amount is mixed with the air.
Thus, there has long been a need for a fuel system for gas powered internal combustion engines wherein both the pressure regulation of the gas, the metering of the gas flow and the combining of the metered gas flow with the air is accomplished in a single unit before introduction of the gas/air mixture into the intake manifold of the engine. Further, in providing such a combination pressure regulator and metering of the gas phase into the air flow in the desired ratio, such single should insure that only gas phase of the fuel is introduced with the ambient air to provide the desired gas/air mixture even though some liquid phase may enter the unit. That is, even if liquid phase enters the unit, the unit must provide that only gas phase is ultimately mixed with the ambient air to provide the desired gas/air mixture for the engine and liquid phase does not enter the engine.
Accordingly, there has long been a need for a carburetor for use in a gas powered internal combustion engine that incorporates both the pressure regulation of the gas as well as the metering of the pressure regulated gas into the air flow to provide the desired gas/air ratio mixture for introduction into the intake manifold of the internal combustion engine.
Accordingly, it is an object of the present invention to provide a combination pressure regulator and carburetor for use in a gas powered internal combustion engine.
It is another object of the present invention to provide a combination pressure regulator and carburetor for use in a gas powered internal combustion engine that minimizes or eliminates any flow of liquid phase of the fuel into the intake manifold of the engine.
It is yet another object of the present invention provide a combination pressure regulator and carburetor for use in a gas powered internal combustion engine wherein the carburetor is positioned in relationship to the internal combustion engine to receive heat therefrom so as to convert any liquid introduced therein into the gas phase.
It is still another object of the present invention to provide a combination pressure regulator and carburetor for use in a gas powered internal combustion engine in which the gas phase of the liquified petroleum gas is metered into the air flow in the desired amount to provide a gas/air mixture corresponding to the operating condition of the internal combustion engine.
It is still another object of the present invention provide a combination pressure regulator and carburetor for use in a gas powered internal combustion engine which may be mounted on the intake manifold or in close proximity thereto so as to absorb heat therefrom.
SUMMARY OF THE INVENTION
The above and other objects of the present invention are achieved, in a preferred embodiment thereof in a carburetor having a body member. The body member has first walls defining a first stage pressure regulating chamber. The first stage pressure regulating chamber may have, in one preferred embodiment of the present invention useful for operation of, for example, a lawn mower, a volume of about 1.6 cubic inches and the first walls may have an area on the order of 11.1 square inches. The first stage pressure regulating chamber has first stage gas inlet port walls defining a first stage gas inlet port into the first stage pressure regulating chamber. The first stage gas inlet port is adapted to be connected to a liquified petroleum gas container which may contain, for example, propane. The liquified petroleum gas container has both the liquid phase and the gas phase of the liquified petroleum gas therein. The gas phase of the liquified petroleum gas is desired for use as the fuel in a gas/fuel mixture for powering an internal combustion engine. The pressure of the gas phase or liquid phase in the liquified petroleum gas container may be on the order of 150 pounds per square inch. The first stage gas inlet port allows the flow of the gas phase or the liquid phase from the liquified petroleum gas container into the first stage pressure regulating chamber. According to the principles of the present invention, the first stage pressure regulating chamber has a comparatively large volume and a comparatively large surface area which aids in ensuring the conversion of any liquid phase of the liquified petroleum gas being converted into the gas phase of the liquified petroleum gas. In a preferred embodiment of the present invention which may be utilized, for example, on a lawn mower, the first stage volume may be on the order of 1.6 cubic inches and the surface area of the first walls of the first stage may be on the order of 8.7 cubic inches.
A first stage diaphragm for regulating gas pressure in the first stage pressure regulating chamber is sealingly mounted in the first stage pressure regulating chamber and is mounted for diaphragm movement towards and away from said first stage gas inlet port. A first stage metering lever pivotally mounted in said first stage pressure regulating chamber and has a first end for movement towards and away from the first stage gas inlet port and a second end spaced from the first end and connected to the first stage diaphragm. A first stage pivot pin is provided in the first stage pressure regulating chamber and the first stage metering lever is pivotally mounted on the first stage pivot pin at a location thereon that is intermediate the first end and the second end thereof. The first end of the first stage metering lever is aligned with the first stage gas inlet port.
For movement of the diaphragm towards the first stage gas inlet port the first end of the first stage metering lever is moved away from the first stage gas inlet port to allow the flow of the gas into the first stage pressure regulating chamber. For movement of the diaphragm away from the first stage gas inlet port, the first end of the first stage metering lever is moved into sealing relationship with the first stage gas inlet port to prevent the flow of gas into the first stage pressure regulating chamber. The first stage pressure regulating chamber diaphragm has an inner surface facing the first stage pressure regulating chamber and an outer surface opposite thereto.
A first stage diaphragm cap is mounted on the body member to cover the first stage diaphragm. A pressure plate is mounted on the first stage diaphragm on the opposite side thereof from the side of the first stage diaphragm facing the first stage pressure regulating chamber. A resilient means such as a first stage coil spring has a first end in contact with the pressure plate and a second end in regions adjacent the first stage diaphragm cap.
A screw member has a first end threadingly mounted in the first stage diaphragm cap and the first end of the screw member is accessible from regions external the body member and the second end of the first stage coil spring bears against the diaphragm pressure plate. The first stage coil spring biases the first stage diaphragm towards the first stage gas inlet port. The first end of the screw member projects to regions external the body member and a control knob is mounted on the first end of the screw member to rotate the screw member and thereby move the first stage diaphragm towards or away from the first stage gas inlet port. When the control knob is rotated in a first direction the first stage diaphragm is moved away from the direction of the first stage gas inlet port thereby causing the first end of the first stage metering lever to block the first stage gas inlet port and prevent the flow of gas into the first stage pressure regulating chamber. When the control knob is rotated in the opposite directions the first stage diaphragm is moved away from the first stage gas inlet port the first end of the first stage metering lever is moved away from the first stage gas inlet port to allow the flow of gas through the first stage gas inlet port and into the first stage pressure regulating chamber.
As the gas phase, gas phase and liquid phase mixture or liquid phase flows into the first stage pressure regulating chamber any liquid phase introduced into the first stage pressure regulating chamber is converted in the first stage pressure regulating chamber of the carburetor to the gas phase. The pressure of the gas on the first stage diaphragm tends to move the diaphragm away from the first stage gas inlet port. The amount of movement of the first stage diaphragm under the pressure of the gas in the first stage pressure regulating chamber that is sufficient to cause the first end of the first stage metering lever to block the first stage gas inlet port is controlled by the biasing force exerted on the diaphragm by the first stage coil spring. The pressure of the gas in the first stage pressure regulating chamber which causes the movement of the first end of the first stage metering lever to block the first stage gas inlet, port is less than the gas pressure of the gas in the liquified petroleum gas storage bottle. The gas pressure in the first stage pressure regulating chamber during operation of the internal combustion engine may be in the range of 10.0 to 50.0 pounds per square inch. The first stage pressure regulating chamber has a volume that, for some applications, may, as noted above, be on the order of 1.6 cubic inches though greater or smaller volumes may be provided for particular applications.
There are second walls in the body member defining a second stage pressure regulating chamber. The second stage pressure regulating chamber has a second stage gas inlet port providing a gas flow passage into said second stage pressure regulating chamber. Gas flow passage walls are provided between the first stage gas outlet port and the second stage gas inlet port to allow the flow of gas from the first stage pressure regulating chamber into the second stage pressure regulating chamber. A second stage diaphragm is sealingly mounted in the second stage pressure regulating chamber for regulating gas pressure in said second stage pressure regulating chamber and is mounted for movement towards and away from said second stage gas inlet port.
A second stage metering lever is pivotally mounted in the second stage pressure regulating chamber and is connected to the second stage pressure regulating chamber diaphragm in manner similar to the mounting of the first stage metering lever and has a first end for movement towards and away from the second stage gas inlet port and a second end spaced from the first end and a pivot pin connection pivotally engaging a second stage pressure regulating chamber pivot pin for providing pivotal mounting thereof intermediate the first end and the second end. Movement of the second end of the second stage metering lever is selectively moved into and out of blocking relationship to the second stage gas inlet port for corresponding movement of the second stage diaphragm away from and towards the second stage gas inlet port to regulate the flow of gas into the second stage pressure regulating chamber to provide a gas pressure in the second stage pressure regulating chamber at a gas pressure lower than the gas pressure in the first stage pressure regulating chamber. The regulated pressure of the gas in the second stage pressure regulating chamber may be on the order of 0.5 pounds per square inch.
For a carburetor having a first stage pressure regulating chamber with the above set forth dimensions, the second stage pressure regulating chamber may have a volume of 0.4 cubic inches and may have a surface area on the order of 7.5 square inches.
The second stage pressure regulating chamber diaphragm has an inner surface facing the second stage pressure regulating chamber and an outer surface opposite thereto. A second stage pressure regulating chamber diaphragm cap is mounted on the carburetor body member over the second stage pressure regulating chamber diaphragm. A second stage pressure plate is attached to the outside face of the second stage pressure regulating chamber diaphragm A second stage pressure regulating chamber resilient means such as a coil spring is mounted between an face of the second stage pressure regulating chamber diaphragm opposite the face thereof facing the second stage pressure regulating chamber and the second stage pressure regulating chamber diaphragm cap for biasing the second stage pressure regulating chamber diaphragm towards the second stage gas inlet port for selectively blocking the second stage pressure regulating chamber gas inlet port to prevent the flow of gas into the second stage pressure regulating chamber. For the condition of the gas pressure in the second stage pressure regulating chamber greater than a predetermined value, the second stage pressure regulating chamber diaphragm is moved away from the second stage pressure regulating chamber gas inlet port and the second end of the second stage pressure regulating chamber metering lever blocks the second stage gas inlet port to prevent the flow of gas into the second stage pressure regulating chamber In general, for most operating conditions of the internal combustion engine all of the fuel flowing from the second stage regulating chamber will be in the gas phase and not the liquid phase.
The body member has third walls defining a metering chamber. The metering chamber has a metering chamber gas inlet port providing a gas flow passage into the metering chamber for accepting a gas flow from said second stage pressure regulating chamber gas outlet port. The metering chamber has a metering chamber gas outlet port for allowing the flow of gas from the metering chamber. A metering chamber diaphragm is sealingly mounted at the metering chamber for regulating the gas flow in the metering chamber and is mounted for movement towards and away from the metering chamber gas inlet port. A metering chamber gas flow lever is pivotally mounted in the metering chamber and has a first end for movement towards and away from the metering chamber gas inlet port and a second end spaced from said first end. The second end of the metering chamber gas flow lever is operatively in contact with the metering chamber diaphragm. A pivot pin is provided in the metering chamber and the metering chamber gas flow lever has a pivotal connection to the pivot pin at a point intermediate the first end and the second end thereof.
A metering spring is provided having a first end bearing against the second end of the metering chamber gas flow lever and as second end bearing against the third walls of the body member to urge the first end of the metering chamber gas flow lever into contact with the metering chamber diaphragm. Movement of the metering chamber diaphragm towards the metering chamber gas inlet port moves the first end of the metering chamber gas flow lever away from the metering chamber gas inlet port and movement of the metering chamber diaphragm away from the metering chamber gas inlet port moves the first end of the metering chamber gas flow lever towards the metering chamber gas inlet port.
A needle member is operatively connected to the second end of the metering chamber gas flow lever and moves therewith. The gas pressure in the metering chamber may be in the range of atmospheric to a small vacuum pressure depending on the speed and load of the internal combustion engine to which the carburetor is attached. For the condition of the gas pressure in the metering chamber greater than a preselected value the needle member is moved into the metering chamber gas inlet port to block the flow of gas into the metering The gas pressure in the metering chamber is less than the gas pressure in the second stage pressure regulating chamber.
A metering chamber diaphragm cap is mounted on the body member and bears against the outside face of the metering chamber diaphragm. The metering chamber has a third gas volume less than second gas volume of the second stage pressure regulating chamber. For the application wherein the second stage pressure regulating chamber has the above specified volume of about 1.0 cubic inches, the metering chamber may have a volume on the order of 0.4 cubic inches.
The body member has fourth walls defining a throttle bore. The throttle bore has an ambient air inlet port for allowing the flow of ambient air from regions external the body member into the throttle bore. The throttle bore also has an outlet port which may be connected to the inlet manifold of the internal combustion engine to be powered by the liquified petroleum gas.
The body member has fifth walls defining a gas flow passage providing communication between the gas outlet port of the metering chamber and the throttle bore to allow the flow of gas from metering chamber into the throttle bore for mixing with the ambient air to provide an gas/air mixture having the desired ratio of liquified petroleum gas to ambient air required to power the internal combustion engine at a flow rate required for the particular operating condition of the internal combustion engine between, for example, idle to full throttle thereof. For a carburetor having the gas volumes specified above for the first stage pressure regulating chamber, the second stage pressure regulating chamber, and the metering chamber it has been found that the gas flow through the carburetor at idle is on the order of 18 cubic inches per minute and the gas flow through the carburetor at full throttle is on the order of 152 cubic inches per minute.
The carburetor has sixth walls in said body member defining a gas/air mixture outlet port for allowing the flow of the gas/air mixture to regions external said body member for connection into an inlet manifold of the internal combustion engine.
The carburetor has seventh walls in said body member and the seventh walls define a throttle control chamber providing communication with the throttle bore. A throttle slide is movably mounted in the throttle control chamber for reciprocating motion therein. A throttle needle is connected to the throttle slide for movement therewith. The throttle needle has a needle end for selective movement into and out of the gas inlet port of the throttle bore for controlling the flow of gas into said throttle bore from said metering chamber from full flow to partially blocking the flow of gas into to the throttle bore for the condition of the throttle needle partially blocking the gas inlet port of the throttle bore. A throttle cable or linkage is operatively connected to the throttle slide for moving the throttle slide in the throttle control chamber. A remote end of the throttle cable extends through a throttle cap to regions external the body member and the remote end of the throttle cable may be connected to the throttle mechanism of the internal combustion engine.
A throttle slide spring is positioned in the throttle cap for biasing the throttle slide toward the position wherein the throttle needle may project into the gas inlet port of the throttle bore to control the flow of gas to either block the flow of gas from the metering chamber gas outlet port partially or not at all depending on how far the needle projects into the throttle bore inlet port of the throttle bore. In some applications it may be desired to provide a limitation on how far the throttle needle projects into the throttle bore gas inlet port. For example, it may be advantageous in use of the internal combustion engine to selectively limit the travel of the throttle needle to a position corresponding to the idle speed of the internal combustion engine. To provide such a limitation, a throttle control pin may be threadingly mounted on the body member and have a first end that may project into the throttle bore so as to limit the movement of the throttle slide to a position where the throttle needle is partially extended into the gas outlet port of the metering chamber at the idle speed of the internal combustion engine.
In preferred embodiments of the present invention, the throttle needle is threadingly attached to the throttle slide so adjustments may be made to provide a desired range of gas/air mixtures for various operating conditions of the engine. In general, the position of the throttle needed relative to the throttle slide is made once at the factory manufacturing the carburetor to adjust the position as necessary because of manufacturing tolerances. The throttle slide and the throttle needle always move together. The engine speed is determined by the position of the throttle slide in the throttle bore which controls the amount of air flowing in the throttle bore and the position of the throttle needle in the metering chamber gas outlet port. For each position of the throttle slide in the throttle bore there is a corresponding position of the throttle needle in the gas flow outlet port of the metering chamber so as to provide the desired gas/fuel ratio for the corresponding engine speed.
In those applications of the present invention utilizing a carburetor having the dimensions above set forth, it has been found that the internal combustion engine may have a power on the order of 3 to 6 horsepower but the dimensions may be appropriately scaled for internal combustion engines having a power of, for example, 0.5 to 20 horsepower.
BRIEF DESCRIPTION OF THE DRAWING
The above and other embodiments of the present invention may be more fully understood from the following detailed description taken together with the accompanying drawing wherein similar reference characters refer to similar elements throughout and in which:
FIG. 1 is a front view of the carburetor according to the principles of the present invention;
FIG. 2 is a view of the carburetor shown in FIG. 1 along the view line 2 - 2 of FIG. 1 ;
FIG. 3 is a view of the carburetor shown in FIG. 1 along the view line 3 - 3 of FIG. 1 ;
FIG. 4 is a view of the carburetor shown in FIG. 1 along the view line 4 - 4 of FIG. 1 ;
FIG. 5 is a sectional of the carburetor shown in FIG. 1 along the section line 5 - 5 of FIG. 3 ;
FIG. 6 is a sectional view of the carburetor shown in FIG. 1 along the section line 6 - 6 of FIG. 1 showing the carburetor at about an idle speed of the internal combustion engine;
FIG. 7 is a sectional view of the carburetor shown in FIG. 1 similar to FIG. 6 showing the carburetor at about a ¾ speed of the internal combustion engine;
FIG. 8 is a view of the carburetor shown in FIG. 1 along the view line 8 - 8 of FIG. 1 ;
FIG. 9 is a partial a sectional view as indicated on FIG. 5 at detail B of a metering chamber gas flow control arrangement in the open position useful in the practice of the present invention;
FIG. 10 is a partial a sectional view similar to FIG. 9 of a metering chamber gas flow control in the closed position useful in the practice of the present invention;
FIG. 11 is a partial sectional view as indicated on FIG. 5 at detail A showing an idle adjustment screw useful in the practice of the present invention;
FIG. 12 is a partial sectional view showing indicated on FIG. 5 at detail C showing the attachment of a lever to a diaphragm and the lever allowing gas flow through the gas outlet port useful in the practice of the preset invention;
FIG. 13 is a partial sectional view similar to FIG. 12 showing the attachment of a lever to a diaphragm and the lever sealing the gas outlet port useful in the practice of the preset invention; and,
FIG. 14 is a block diagram showing the preferred attachment arrangement of the carburetor of the present invention to the inlet manifold of an internal combustion engine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the Figures of the drawing and in particular to the sectional view of FIG. 5 , there is shown a preferred embodiment generally designated 10 of the present invention of a carburetor 12 according to the principles of the present invention. The carburetor 12 has a body member 14 . The body member 14 has first walls 16 defining a first stage pressure regulating chamber 18 . The body member 14 also has first stage gas inlet walls 20 defining a first stage gas inlet port 22 . The first stage gas inlet port 22 is adapted to be connected to a liquified petroleum gas container indicated at 24 which contains both the liquid phase and the gas phase of the liquified petroleum gas therein and the liquified petroleum gas may, for example, be propane. The gas phase of the liquified petroleum gas flows out of the liquified petroleum gas container 24 as indicated by the arrow 26 into the first stage gas inlet port 22 and into the first stage pressure regulating chamber 18 . Depending upon the operating conditions of the carburetor 12 , some of the liquid phase or a mixture of the liquid phase and gas phase of the liquified petroleum gas may also enter the first stage pressure regulating chamber 18 . Any liquid phase of the liquified petroleum gas that flows into the first stage pressure regulating chamber is converted by the heat absorbed from the walls 16 of body member 14 of the carburetor 12 to the gas phase. The pressure of the gas phase and/or the liquid phase of the liquified petroleum gas in the liquified petroleum gas container 24 may be on the order of 150 pounds per square inch.
A first stage diaphragm 28 is sealingly mounted on the body member 14 in the first stage pressure regulating chamber 18 and provides diaphragm type movement towards and away from the first stage gas inlet port 22 . As utilized herein, “diaphragm movement” refers to that type of movement of a diaphragm wherein the diaphragm is mounted along the edges and the center of the diaphragm moves in response to forces exerted on the diaphragm. A first stage metering lever 30 is pivotally mounted on pivot pin 32 contained in the first stage pressure regulating chamber 18 . The first stage metering lever 30 has a first end 34 that moves towards and away from the first stage gas inlet port 22 and a second end 36 spaced from the first end 34 coupled to the first stage diaphragm 28 . The pivot pin 32 is intermediate the first end 32 and second end 34 of the first stage metering lever 30 so that movement of the diaphragm 18 towards the first stage gas inlet port 22 in the direction of the arrow 158 ( FIG. 13 ) causes the first end 34 of the first stage metering lever to be retracted from the first stage gas inlet port 22 and movement of the first stage diaphragm 28 away from the first stage gas inlet port 22 in the direction of the arrow 160 ( FIG. 13 ) causes the first end 34 of the first stage metering lever 34 to move towards the first stage inlet port 22 until sufficient such movement of the first stage diaphragm 28 causes the first end 34 of the first stage metering lever 30 to seal the first stage gas inlet port 22 thereby preventing the flow of liquified petroleum gas or liquid phase thereof into the first stage pressure regulating chamber 18 . The first stage diaphragm 28 has an inner face 28 a facing the first stage pressure regulating chamber 18 and an outer face 28 b opposite thereto.
A first stage diaphragm cap 38 is mounted on the body member 14 by, for example mounting screws 170 ( FIG. 13 ) to cover the first stage diaphragm 18 . A pressure plate 40 is mounted on the outer face 28 b of the first stage diaphragm 18 . A resilient means such as coil spring 42 has a first end 42 a bearing against the pressure plate 40 and a second end 42 b in regions adjacent the first stage diaphragm pressure cap 38 . A screw member 44 is provided that has a first end 44 a that threadingly engaging the first stage diaphragm cap 38 as indicated at 46 . The second end 42 b of the coil spring 42 bears against the pressure plate 40 . The first end 44 a of screw means 44 can extend to regions external the carburetor 12 and a control knob 48 is coupled to the first end 44 a of the screw means 44 to rotate the screw means 44 . As the screw means 44 is rotated by the control knob 48 in a first direction, the first stage diaphragm 28 is moved towards the first stage gas inlet port 22 and as the screw means 44 is rotated by the control in a second direction opposite the first direction the diaphragm 28 is moved away from the gas inlet port 22 .
As shown in greater detail on FIG. 13 , as the gas phase, gas phase and liquid phase mixture or liquid phase of the liquified petroleum gas flows into the first stage pressure regulating chamber through the first stage gas inlet port 22 , any liquid phase is converted to the gas phase and the pressure of the gas on the first stage diaphragm 28 causes the first stage diaphragm 28 to move in the direction of the arrow 160 away from the first stage gas inlet 22 thereby causing the first end 34 of the first stage metering lever 30 to move towards the first stage gas inlet port 22 until a preselected pressure is reached and at that preselected pressure the first end 34 of the first stage metering lever 30 moves into sealing relationship with the first stage gas inlet port 22 thereby preventing the flow of gas into the first stage pressure regulating chamber. The amount of movement of the first stage diaphragm 28 which will cause the sealing of the first stage gas inlet port 22 is controlled by the amount of pre-loading bias on the first stage diaphragm by the coil spring 42 and the gas pressure in the first stage pressure regulating chamber. As the first stage diaphragm 28 moves toward the first stage gas inlet port 22 in the direction of the arrow 158 ( FIG. 12 ) the first end 34 of the first stage metering lever 30 moves away from the first stage gas inlet port 22 allowing the flow of gas phase and/or liquid phase of the liquified petroleum gas from container 24 to flow into the first stage pressure regulating chamber 18 . In some applications of the present invention it may be advantageous to vent the outer face 28 b of the first stage diaphragm 28 . To accomplish such venting, an aperture 28 a is provided in the diaphragm cap 28 to allow communication of the volume between the outer face 18 a and the diaphragm cap 28 to be exposed to ambient air at the ambient air pressure.
During operation, the gas pressure of the liquified petroleum gas in the first stage pressure regulating chamber is less than the pressure of the liquified petroleum gas phase in the liquified petroleum gas container 24 . The operating pressure of the liquified petroleum gas in the first stage pressure regulating chamber may be in the range of 10.0 to 50.0 pounds per square inch. The first stage pressure regulating chamber 18 also has a first stage gas outlet port 18 a . In one particular application of the principles of the present invention in the embodiment 10 , the volume of the first stage pressure regulating chamber may be on the order of 1.6 cubic inches.
The body member 14 has second walls 50 defining a second stage pressure regulating chamber 52 . The second stage pressure regulating chamber 52 has walls 54 defining a second stage gas inlet port 54 which receives gas from the first stage gas outlet port 18 a in the first stage pressure regulating chamber 18 . The body member has walls 56 defining a gas flow passage channel 58 extending from the first stage gas outlet port 18 a which provides gas flow communication to allow the flow of gas from the first stage pressure regulating chamber 18 into the second stage gas inlet port 54 and into the second stage pressure regulating chamber 52 .
A second stage pressure regulating chamber diaphragm 60 is sealingly mounted on the body member 14 for regulating the pressure in the second stage pressure regulating chamber 52 in a manner similar to the mounting of the first stage diaphragm 28 described above. The second stage pressure regulating diaphragm 60 has an inner face 60 a facing the second stage pressure regulating chamber and an outer face 60 b opposite thereto. A second stage metering lever 62 is pivotally mounted by pivot pin 64 in the second stage pressure regulating chamber 52 and the second stage metering lever 62 has a first end 66 which is movable into and out of sealing relationship with second stage gas inlet port 54 . A second end 68 of the second stage metering lever 62 is attached to the second stage pressure regulating chamber diaphragm as indicated at 70 in the same manner as described above for the first stage metering lever 30 . Movement of the first end 66 into and out of sealing relationship with the second stage inlet port 54 is controlled by the corresponding movement of the second stage pressure regulating chamber diaphragm 60 away from and towards, respectively, the second stage gas inlet port 54 in a manner similar to the action of the first stage metering lever 30 described above. The pressure of the gas in the second stage pressure regulating chamber 52 is on the order of 0.5 pounds per square inch. For a carburetor embodiment 10 in which the volume of the first stage pressure regulating chamber 18 is on the order of 1.6 cubic inches as described above, the volume of the second stage pressure regulating chamber 52 is on the order of 1.0 cubic inches.
A second stage pressure regulating chamber diaphragm cap 70 is mounted on the carburetor body 14 by screws 170 over the second stage pressure regulating chamber diaphragm 60 . A second stage pressure regulating chamber resilient means such as the coil spring 72 has a first end 72 a bearing against the second stage pressure regulating chamber diaphragm cap 70 and a second end 72 b bearing against a pressure plate 74 which is mounted on the outer surface 60 b of the second stage pressure regulating chamber diaphragm 60 . The coil spring 72 urges the second stage pressure regulating chamber diaphragm 60 towards the second stage gas inlet port 58 . For the condition of the gas pressure in the second stage pressure regulating chamber 52 above a preset second stage pressure regulating chamber value, the second stage pressure regulating chamber diaphragm 60 is moved away from the second stage gas inlet port 54 causing the first end 66 of the second stage metering lever 62 to block the second stage gas inlet port 54 thereby preventing the further flow of gas into the second stage pressure regulating chamber 52 . The pressure of the gas in the second stage pressure regulating chamber 52 is controlled by the pressure of the gas therein and the biasing force exerted on the second stage pressure regulating chamber diaphragm 60 by the coil spring 72 . The operation of the second stage pressure regulating chamber diaphragm 60 and second stage metering lever is the same as described above in connection with the first stage pressure regulating chamber diaphragm 28 and first stage metering lever 34 and as illustrated in the detail showing on FIGS. 12 and 13 .
The carburetor body 14 has third walls 80 defining a metering chamber 82 . The metering chamber 82 has a metering chamber gas inlet port 84 that is in gas flow communication with the second stage pressure regulating chamber 52 to allow the flow of gas from the second stage pressure regulating chamber 52 into the metering chamber 82 . The metering chamber 82 also has a gas outlet port 86 to allow the flow of gas from the metering chamber 82 . The metering chamber 82 and the structure associated therewith serves the primary purpose of metering the flow of gas phase liquified petroleum gas into the metering chamber 82 .
A metering chamber diaphragm 88 is sealingly mounted to the carburetor body 14 at the metering chamber 82 for regulating the gas pressure in the metering chamber 82 and is mounted for movement towards and away from the metering chamber gas inlet port 84 . As shown on FIG. 5 and in more detail on FIGS. 9 and 10 , there is provided a metering chamber gas flow lever 90 having a first end 90 a operatively connected to a metering needle 94 . The metering chamber gas flow lever 90 has a second end 90 b operatively connected to the metering chamber diaphragm 88 . A biasing spring 200 has a first end 200 a abutting the third walls 80 which define the metering chamber 82 . The biasing spring 200 has a second end 200 b which abuts against the second end 90 b of the metering lever 90 in regions adjacent to the location of the operative contact between the metering chamber diaphragm 88 and the metering chamber gas flow lever 90 . The biasing spring biases the metering chamber diaphragm in the direction of the arrow 210 ( FIGS. 9 and 10 ). The metering needle 94 has a first end 94 a aligned with the metering chamber gas inlet port 84 and, with the movement of the metering chamber diaphragm 88 , moves into and out of the metering chamber gas inlet port 84 to selectively block and allow the flow of gas into the metering chamber 82 as illustrated in detail on FIGS. 9 and 10 . The metering chamber diaphragm 88 has an inner face 88 a facing the metering chamber 82 and an outer face 88 b opposite thereto.
A pivot pin 96 is mounted in the metering chamber 82 and the metering chamber gas flow lever 90 is mounted on the pivot pin at a point between the first end 90 a and second end 90 b thereof for pivotal movement thereon.
A metering chamber diaphragm back up plate 98 is coupled to the carburetor body 14 and bears against the outer face 88 b of the metering chamber diaphragm 88 . The metering chamber diaphragm back up plate 98 has an aperture 98 a having a preselected area which allows ambient atmospheric air at the ambient air pressure to act upon the outer face 88 b of the metering chamber diaphragm 88 . The outer face 88 b of the metering chamber diaphragm 88 is exposed to ambient air pressure because of the aperture 98 a in diaphragm back up plate 98 . The biasing spring 200 tends to move the metering chamber diaphragm 88 in the direction of the arrow 210 ( FIGS. 9 and 10 ) thereby tending to move the first end 94 a of the metering needle 94 into engagement with the metering chamber gas inlet port 84 . For the condition of the first end 94 a of metering needle 94 fully engaging the metering gas chamber inlet port 84 as shown on FIG. 10 the flow of gas into metering chamber 82 is blocked. For the condition of the gas pressure in metering chamber 82 decreasing to a predetermined value lower than the atmospheric air pressure, the force of the atmospheric air pressure on the outer face 88 b of the metering diaphragm 88 becomes sufficient to overcome the force of the gas pressure on the inner face 88 a of the metering diaphragm 88 and the force of the biasing spring 200 , the metering chamber diaphragm 88 moves in the direction of the arrow 190 ( FIGS. 9 and 10 ) thereby opening metering chamber gas inlet port 84 to allow the flow of gas into metering chamber 88 as shown in FIG. 9 .
The a bearing plate 88 ′ may, if desired, be coupled to the inner face 88 a of the metering chamber diaphragm 88 to provide additional support for the action of the diaphragm 88 against the second end 90 b of the metering lever 90 .
The metering chamber 82 has a volume, for a carburetor having the dimensions as above set forth, in the range of 0.4 cubic inches. The gas pressure in the metering chamber 82 for the carburetor having the dimensions and gas pressures as above described is on the order of atmospheric to a partial vacuum depending on the speed and load conditions of the internal combustion engine to which the carburetor 14 is operatively connected.
As shown on FIGS. 5 , 6 and 7 , the carburetor body has fourth walls 100 defining a throttle bore 102 . As described below in greater detail, the throttle bore 100 has an air inlet port 104 and a gas/air outlet port 106 and the gas outlet port 106 is adapted to be connected to the intake manifold of an internal combustion engine for delivering thereto a gas/fuel mixture having a preselected gas to air ratio for the particular operating conditions of the internal combustion engine.
The carburetor body has fifth walls 108 defining a gas flow passage 110 which provides gas flow communication between the metering chamber 82 and the throttle bore 102 to allow the flow of gas from the metering chamber 82 into the throttle bore 102 . The diameter of the throttle bore 102 is smaller than the air inlet port 104 and the gas/air outlet port 106 . This creates a venturi when air flow is drawn through the throttle bore 102 by the suction applied by the internal combustion engine. As the flow of air passes into the reduced diameter throttle bore 102 , the speed of the airflow increases and the pressure decreases. The now lower than ambient air pressure present in the throttle bore 102 is connected by the metering chamber outlet passage 110 to the metering chamber 82 . The greater atmospheric pressure present on the metering chamber diaphragm outer surface 88 a causes the metering chamber diaphragm 88 to move towards the metering chamber inlet port 84 , which in turn causes the metering chamber needle 94 to lift from the metering chamber gas inlet port which allows the flow of liquefied petroleum gas into the metering chamber 82 . The flow of gas continues into the metering chamber outlet port 110 and thus into the throttle bore 102 . The gas mixes with ambient air in the throttle bore 102 to provide a gas/air mixture with the desired ratio of liquified petroleum gas to air required by the internal combustion engine at a flow rate required by the particular operating conditions of the internal combustion engine. For a carburetor having the dimensions and configurations as above described, it has been found that the gas flow through the carburetor from the gas inlet port 22 to the throttle bore 102 may be on the order of 18 cubic inches per minute at idle to a gas flow rate on the order 152 cubic inches per minute for the internal combustion engine at full throttle.
As shown on FIGS. 6 and 7 , there are sixth walls 110 in the throttle inlet port 102 defining the gas/air mixture outlet port 106 for introduction of the gas/air mixture into the inlet manifold of an internal combustion engine to be powered by the liquified petroleum gas.
The carburetor has seventh walls 112 defining a throttle control chamber 114 . A throttle slide 116 is mounted for sliding movement in the throttle control chamber 114 in the directions indicated by the double ended arrow 118 . A throttle needle 120 is mounted on the throttle slide 116 for reciprocating motion therewith in the directions indicated by the double ended arrow 118 . The throttle needle 120 has a needle end 120 a for selective movement into and out of a gas inlet port 124 to meter the flow of gas into the throttle bore from full flow wherein the first end of the needle 120 a is retracted from the gas inlet port 124 to a position where the first end 120 a of the needle 120 partially blocks the aperture in the insert 128 to reduce the flow of gas into the throttle bore 102 at an idle speed of the internal combustion engine. The taper of the needle end 120 a of the throttle needle 120 is shaped to partially block the aperture in insert 128 at any position of between fully open throttle slide 116 and a fully closed position to provide the metering function of the correct gas/air ratio for the specific internal combustion engine at any engine speed or load. The throttle needle 120 is threadingly attached to the throttle slide 116 as indicated at 119 for movement therewith. By rotating the throttle needle at the threading engagement 119 , an adjustment of the gas/air ratio is achieved. A throttle cable 130 is operatively connected to the throttle slide to move the throttle slide in the direction indicated by the upper arrow 118 a when the contact ball 132 engages the upper end 116 a of the throttle slide 116 . A throttle cap 140 is threadingly connected to the carburetor body 14 as indicated at 142 and a throttle spring 144 is mounted in the throttle cap 140 and has a first end 144 a bearing against the upper end 116 a of the throttle slide 116 and a second end 144 b bearing against the throttle cap 140 to bias the throttle slide 116 in the direction of the second arrow 118 b.
In some applications of a carburetor according to the principles of the present invention, it may be desirable to provide a throttle slide movement limitation 220 on the travel of the throttle slide 116 towards the gas inlet port 124 to thereby limit the penetration of the throttle needle 120 into the gas inlet port 124 . FIG. 11 illustrates the details of the throttle slide movement limitation 220 . As shown thereon, there are walls 222 in the body member 14 in regions adjacent the throttle bore 102 defining a limitation chamber 224 . A control needle 226 threadingly engages the body member 14 as indicated at 228 . The control needle 226 has a first end 226 a that may be moved into the throttle bore 102 as indicated by the dotted line showing at 230 by rotating the adjustment end 226 b of the control needle 226 . For the first end 226 a of the control needle 226 projecting onto the throttle bore as shown by the dotted line, the throttle slide 116 engages the first end 226 a and thus downward movement of the throttle slide 116 is stopped at a predetermined position corresponding to the desired minimum opening of the gas inlet port 128 . A control needle spring 244 is positioned in the limitation chamber 224 and abuts the body member 14 and the second end 226 b of the control needle 226 to bias the control needle 226 outwardly.
The carburetor 12 may be provided with flanges 240 having apertures 242 therethrough which may be utilized for attachment of the carburetor to the internal combustion engine as desired.
FIG. 14 illustrates a block diagram showing the preferred mounting relationship between the carburetor, an intake manifold and an internal combustion engine. As shown on FIG. 14 , a carburetor 150 , which may be the same as carburetor 12 described above, receives ambient air indicated by the arrow 180 and gas phase/liquid phase liquified petroleum gas such as propane, as indicated by the arrow 182 . The carburetor 150 converts any liquid phase liquified petroleum gas entering the carburetor 150 into the gas phase thereof and mixes the gas phase with the ambient air in a preselected gas to air ratio and provides the gas/air mixture at the outlet thereof, as indicated by the arrow 184 , as described above for the operation of carburetor 12 . The carburetor 150 is mounted on or in close proximity to an intake manifold 152 of an internal combustion engine 154 so as to be in heat receiving relationship thereto. That is, in the preferred embodiments of the present invention the carburetor such as the carburetor 150 , which may be the same as carburetor 12 , shown in the block diagram of FIG. 14 , is in heat receiving relationship to the internal combustion engine 154 so that the carburetor 150 receives heat by any or all of the heat transfer modes of radiation, conduction and convection from the engine and/or and structural parts thereof and/or and accessories thereof. The heat received by the carburetor 150 supplies the necessary energy to convert any liquid phase of the liquified petroleum gas which enters the first stage pressure regulator chamber of the carburetor into the gas phase. The intake manifold 152 directs the gas/fuel mixture as shown by the arrow 186 to the cylinders 154 a of the internal combustion engine 154 which may be connected to any desired device (not shown) to provide the operation thereof.
As noted above, the diaphragms 40 , 60 and 88 are sealingly mounted on the body member 14 . FIGS. 9 , 10 and 11 illustrate a preferred sealing arrangement. The diaphragms are provided with a knife edge that bears against the body member 14 and the force of the back up plates bearing against the diaphragms provides the desired sealing engagement. However, other sealing arrangements may be utilized as desired in particular applications.
Although specific embodiments of the present invention have been described above with reference to the various Figures of the drawing, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims. While the particular embodiments and applications of the present invention have been above described and illustrated, the present invention is not limited to the precise construction and arrangements disclosed. Those persons knowledgeable in the art may also conceive of certain modifications, changes and variations in the precise details of the embodiments disclosed above for adaptation of the principles of the present invention to various applications to suit particular circumstances or products to be formed. The invention is therefore not intended to be limited to the preferred embodiments depicted, but only by the scope of the appended claims and the reasonably equivalent apparatus and methods as described herein.
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A carburetor for a gas powered internal combustion engine having a plurality of pressure reducing stages for reducing the pressure of the gas phase in a liquified petroleum gas storage bottle prior to the mixing of the gas phase of the liquified petroleum gas with ambient air.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This patent application claims priority, under 35 USC 119, from Korean Patent Application No. 10-2006-0003547 filed on Jan. 12, 2006, the entire content of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mask for silicon crystallization, a method for crystallizing silicon using the same and a display device. More particularly, the present invention relates to a mask for silicon crystallization, wherein the number of grain boundaries of crystallized silicon can be minimized, a method for crystallizing silicon using the mask and a display device.
2. Description of the Related Art
In a liquid crystal display (LCD), the amount of light transmitted through the liquid crystal (LC) panel is adjusted according to an image signal. The image signal is applied to a plurality of control switches arranged in a matrix, so that a desired image can be displayed on the LCD panel. An LCD is classified into an amorphous silicon thin film transistor (TFT) LCD and a polysilicon TFT LCD. A polysilicon TFT exhibits superior device characteristics to an amorphous silicon TFT, and a driving circuit can be mounted on a substrate of the polysilicon TFT. A crystallizing method for obtaining such a polysilicon thin film includes a variety of methods such as solid phase crystallization (SPC), rapid thermal annealing (RTA), excimer laser annealing (ELA) and sequential lateral solidification (SLS).
FIG. 1A is a schematic illustration of a sequential lateral solidification (hereinafter, referred to as “SLS”) technique, and FIG. 1B is a schematic view of silicon crystallized by the SLS technique.
The SLS technique is a technique for crystallizing amorphous silicon after locally melting the amorphous silicon by using a slit formed in a mask. As compared with the existing ELA technique, the SLS technique has several advantages. For example, a variety of particle sizes (a few μm to a single crystal) can be achieved as desired, process margin is increased, and productivity is greatly enhanced because there is no limitation for the substrate size and no vacuum is required. Accordingly, much attention to the SLS technique has been paid as the next-generation crystallization technique. As shown in FIG. 1A , a laser beam passes through a slit 15 formed in a mask 10 , melting the amorphous silicon locally. The slit is about a few μm long. A melted region 25 of a substrate 20 crystallizes as it is cooled, such that the crystals grow from the boundary between the melted region 25 and a neighboring unmelted region 27 . The crystals grow toward the center of the melted region 25 and stops growing when particles meet one another at the center. The aforementioned process is repeated while moving the slit 15 little by little over the substrate 20 , eventually crystallizing the entire substrate 20 .
FIG. 1B shows a state where amorphous silicon has been crystallized using a straight slit. In this figure, the arrows designate crystal growth directions. When using such an SLS technique, the shape and size of a particle formed can be changed depending on the shape of the slit.
FIG. 2 schematically illustrates the process of a general single scan two-shot SLS. Referring to FIG. 2 , when a shot of laser beam (first shot) is directed onto an amorphous silicon thin film using a mask with a plurality of slits, melted portions 25 a and 25 b are formed. The melted portions crystallize as they cool. The entire substrate can be crystallized by repeating the process of irradiating portions of the substrate with a laser beam (by using a second shot, third shot , . . . , and n-th shot) while moving a mask over the substrate between the shots.
FIGS. 3A and 3B are graphs showing the characteristics of a TFT that uses the silicon crystallized by the SLS process of FIG. 2 . FIG. 3A is a graph plotting the characteristics of a TFT with a TFT channel formed in a horizontal direction, i.e. a crystal growth direction, and FIG. 3B is a graph plotting the characteristic of a TFT with a TFT channel formed in a vertical direction. A particle size nearly corresponding to the slit size is obtained in the horizontal direction (crystal growth direction), while a small particle size corresponding to about a few thousands angstroms (Å) is obtained in the vertical direction.
Referring to FIGS. 3A and 3B , the characteristics of a TFT, e.g. I on (for Vds=10.1 and Vgs=20) and electron mobility (for Vds=10.1), are shown in the following Table 1.
TABLE 1
Characteristics
Direction
I on (μA)
Electron Mobility (cm 2 /Vs)
Horizontal Direction
750~900
100~120
Vertical Direction
200~330
~30
As illustrated in Table 1, the I on (μA) and electron mobility (cm 2 /Vs) in a horizontal direction are about 750 to 900 and about 100 to 120, respectively. Further, the I on (μA) and electron mobility (cm 2 /Vs) in a vertical direction are about 200 to 330 and up to about 30, respectively. That is, it can be understood that the horizontal characteristics are markedly better than the vertical characteristics. Due to such directional anisotropy, a TFT channel should be designed in only one direction when a circuit for a system-on-glass (SOG) product is built in a panel. This is an undesirable limitation. An SLS technique in which a two-shot SLS process is performed twice, once in a horizontal direction and another time in a vertical direction, has been conceived to overcome the limitation. According to the SLS technique, at least theoretically, the growth can be achieved in both horizontal and vertical directions. That is, a uniform microstructure with no anisotropic property in the horizontal and vertical directions can be obtained after the crystallization, and thus, the uniform characteristics can also be obtained.
FIGS. 4A and 4B are a view and photograph showing a microstructure of silicone crystallized using only a horizontal silt, respectively; FIGS. 4C and 4D are a view and photograph showing a microstructure of silicone crystallized using both horizontal and vertical silts, respectively.
Referring to FIGS. 4A to 4D , if a mask including both horizontal and vertical slits is used, a particle grown through one slit becomes a seed and grows perpendicularly to the direction of a particle grown through the next slit. However, if the vertical slit does not precisely align with one row of particles between horizontal grain boundaries but simultaneously aligns with parts of two rows of particles as shown in FIGS. 4A and 4C , the problem of anisotropic property in the particle is not completely solved since a sub grain boundary forms perpendicularly to the original grain boundary, as indicated by the circles in FIG. 4C . Since an actual grain boundary is almost never a perfectly straight line, such a phenomenon occurs frequently. Accordingly, the existing 2+2 shot SLS process is not a great improvement relative to the two-shot SLS process, at least from the perspective of limitations imposed by the anisotropic property.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a mask for silicon crystallization in which design constraints associated with anisotropic properties in both horizontal and vertical directions are overcome. The mask has a first, a second, third, and a fourth group of slits that are spaced apart from one another in the scan direction. In each group of slits, the slits are spaced apart from one another in a direction perpendicular to a scan direction. The first and second groups of slits are inclined to form an obtuse angle with respect to the scan direction. The third and fourth groups of slits are inclined to form an acute angle with respect to the scan direction.
In another aspect, the invention is a mask for silicon crystallization that includes a first group of slits that form a first predetermined angle with respect to a scan direction and a second group of slits that form a predetermined angle with respect to the first group of slits.
In yet another aspect, the invention is a method for crystallizing silicon using the above-described mask for silicon crystallization. The method may entail forming a silicon thin film on a substrate, placing a mask over the substrate such that slits in the mask form an angle between about 5 degrees and about 85 degrees with respect to an edge of the substrate, positioning the slits over a preselected region of the substrate, irradiating the preselected region through the slits to melt the silicon in the preselected region; and allowing the preselected region to cool.
In yet another aspect, the present invention is a display device that includes a polysilicon thin film of which grain and sub-grain boundaries are inclined at an angle between about 5 and about 85 degrees with respect to the edges of a substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become apparent from the following description of a preferred embodiment given in conjunction with the accompanying drawings, in which:
FIG. 1A is a view schematically showing a basic principle of a sequential lateral solidification (SLS) technique among general crystallization techniques, and FIG. 1B is a schematic view of silicon crystallized by the SLS technique;
FIG. 2 schematically illustrates a sequential progress for a general single scan two-shot SLS;
FIGS. 3A and 3B are graphs showing the characteristics of a thin film transistor (TFT) using silicon crystallized by the SLS process of FIG. 2 ;
FIGS. 4A and 4B are a view and photograph showing a microstructure of silicone crystallized using only a horizontal silt, respectively; FIGS. 4C and 4D are a view and photograph showing a microstructure of silicone crystallized using both horizontal and vertical silts, respectively.
FIG. 5 is a view showing a mask for silicon crystallization according to the present invention;
FIG. 6 is a view schematically showing the shape of a silicon particle crystallized using the mask for silicon crystallization according to the present invention;
FIG. 7 schematically shows a sequential SLS process using the mask for silicon crystallization according to the present invention; and
FIGS. 8A to 8D are graphs, respectively, plotting characteristics of TFTs in which channels are formed in horizontal and vertical directions of a substrate with a crystallized silicon thin film formed therein according to an SLS process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. As used herein, the terms “horizontal” and “vertical” are used in reference to the drawings.
FIG. 5 shows a mask for silicon crystallization according to the present invention.
More specifically, FIG. 5 shows a mask 100 formed with a first group of slits 101 , a second group of slits 102 , a third group of slits 103 and a fourth group of slits 104 .
The mask 100 includes the first, second, third and fourth groups of slits 101 , 102 , 103 and 104 , each of which is formed inclined at a predetermined angle with respect to a scan direction, such that a laser beam can be selectively transmitted through the mask 100 . As used herein, “scan direction” is the direction in which the mask 100 is moved over the substrate. Each of the first to fourth groups of slits 101 to 104 includes a plurality of slits. Although the mask 100 includes only one row of slits in each group for this particular embodiment, the present invention is not limited thereto. That is, there may be multiple rows of slits in each group arranged on the mask 100 .
The first group of slits 101 includes a plurality of slits, each of which is inclined at an obtuse angle with respect to the scan direction. The plurality of slits are arranged to be spaced apart from each other by a predetermined interval in a direction perpendicular to the scan direction. Each slit is about 4 to 6 μm wide but the width may be adjusted as desired. In this embodiment, the first group of slits 101 is formed to be inclined at about 135 degrees with respect to the scan direction.
The second group of slits 102 includes a plurality of slits, each of which is inclined at an obtuse angle with respect to the scan direction. The plurality of slits are arranged to be spaced apart from each other by a predetermined interval in a direction perpendicular to the scan direction. Each slit is about 4 to 6 μm wide but the width may be adjusted as desired. In this embodiment, the second group of slits 102 is formed to be inclined at about 135 degrees with respect to the scan direction. The slits in the second group of slits 102 are arranged to be substantially parallel with those of the first group of slits 101 . If the first group of slits 101 and the second group of slits 102 are arranged close to each other, they are arranged in a staggered manner such that the two groups of slits do not overlap each other or connect to form long slits.
The third group of slits 103 comprises a plurality of slits, each of which is inclined at an acute angle with respect to the scan direction. The plurality of slits are arranged to be spaced apart from each other by a predetermined interval in a direction perpendicular to the scan direction. In this embodiment, the third group of slits 103 is formed to be inclined at about 45 degrees with respect to the scan direction. Each slit is about 4 to 6 μm wide but the width may be adjusted as desired.
The fourth group of slits 104 comprises a plurality of slits, each of which is inclined at an acute angle with respect to the scan direction. The plurality of slits are arranged to be spaced apart from each other by a predetermined interval in a direction perpendicular to the scan direction. In this embodiment, the fourth group of slits 104 is formed to be inclined at about 45 degrees with respect to the scan direction. Each slit is about 4 to 6 μm wide but the width may be adjusted as desired.
The slits of the fourth group of slits 104 are arranged to be parallel with those of the third group of slits 103 . If the third group of slits 103 and the fourth group of slits 104 are arranged close to each other, they are arranged in a staggered manner such that the two groups of slits do not overlap each other or connect to form long slits.
The first to fourth groups of slits 101 to 104 are arranged to be adjacent to one another as described above in the embodiment shown in FIG. 5 , but the present invention is not limited to the embodiment shown. For example, the specific arrangement of the groups of slits may be changed. In some embodiments, the third or fourth group of slits 103 or 104 may be arranged between the first group of slits 101 and the second group of slits 102 .
FIG. 6 is a view schematically showing the shape of a silicon particle crystallized using the mask for silicon crystallization according to the present invention.
Referring to FIG. 6 , if the aforementioned mask 100 is aligned on an amorphous silicon thin film formed on a substrate and irradiated with a laser beam, silicon in a select region on the substrate is crystallized by the first group of slits 101 in a direction inclined at a predetermined angle, e.g. 95 to 175 degrees, and preferably 135 degrees, with respect to the scan direction on the substrate. The other uncrystallized portions are crystallized by the second group of slits 102 , which is parallel to and staggered with the first group of slits 101 , so that the predetermined region on the substrate has silicon particles crystallized and grown in a direction inclined at 135 degrees with respect to the scan direction on the substrate.
Further, if a laser beam is directed onto the region crystallized by the first and second groups of slits 101 and 102 through the third and fourth groups of slits 103 and 104 arranged in a direction perpendicular to the first and second groups of slits 101 and 102 , the crystal is again grown in a direction perpendicular to a crystal growth direction obtained by the first and second groups of slits 101 and 102 . As shown in FIG. 6 , a silicon particle is consequently crystallized and grown in the shape of a rectangle or square, i.e. rhombus, arranged to be rotated by a predetermined angle, e.g. 5 to 85 degrees, and is preferably 45 degrees, with respect to a horizontal or vertical edge of the substrate. Since a silicon particle crystallized and grown in the manner described above form a crystalline region that is inclined at about 45 degrees, even though a grain boundary exists, there is hardly a difference between the vertical and horizontal characteristics.
FIG. 7 schematically shows a sequential SLS process using the mask for silicon crystallization according to the present invention.
Referring to FIG. 7 , a substrate with a silicon thin film formed thereon is first prepared.
Next, the mask 100 as described above and shown in FIG. 5 is positioned above the substrate such that the location of the mask 100 is aligned with the target zone on the substrate.
Then, the substrate on which the mask 100 is arranged is irradiated with a laser beam. That is, a shot of laser beam (first shot) is shone onto the amorphous silicon thin film through the first to fourth groups of slits 101 to 104 of the mask 100 simultaneously. If the laser beam is irradiated in such a manner, regions on the amorphous silicon thin film corresponding to the locations of the first to fourth groups of slits 101 to 104 are melted and then crystallized as they are cooled.
The process of irradiating a laser beam is repeated (second shot, third shot , . . . , or n-th shot) while moving a stage mounted with the substrate by one group of slits (alternatively, the mask may be moved while the substrate stays still or both the mask and the substrate may be moved). For example, the region that was covered by the fourth group of slits during the first shot will be covered by the third group of slits during the second shot, the second group of slits during the third shot, etc. This moving of the substrate and/or the mask is repeated until the entire regions of the amorphous silicon thin film formed on the substrate are crystallized in such a manner that a first scan is performed from one end to the opposite end of the substrate. Then, the stage is moved to a neighboring region, e.g. a region beneath the first scan, and a second scan is performed in a direction opposite to that of the first scan. If the SLS process is performed in the manner described above, the laser beam is irradiated four times in a state where the first to fourth groups of slits 101 to 104 are sequentially arranged in a predetermined region on the amorphous silicon thin film formed on the substrate, so that the crystallization of the silicon on the predetermined region is completed.
In some embodiments, the SLS process may be performed using a mask including a group of slits formed in a horizontal direction and group of slits formed in a vertical direction rather than the mask 100 shown in FIG. 5 . In this case, a substrate with an amorphous silicon thin film formed thereon is first prepared. Next, the mask is aligned, and a stage mounted with the substrate is positioned to be inclined at a predetermined angle with respect to the mask.
Then, the substrate on which the mask is arranged is irradiated with a laser beam. That is, the laser beam is directed onto the amorphous silicon thin film through groups of slits in the mask. If the laser beam is irradiated in such a manner, regions of the amorphous silicon thin film corresponding to the locations of the slits are melted and then crystallized as they are cooled. If the SLS process is performed in the manner described above, a silicon particle is crystallized and grown in the shape of a rectangle (e.g., a square, a rhombus), arranged to be inclined by a predetermined angle (e.g. 5 to 85 degrees, and preferably 45 degrees) with respect to the horizontal or vertical direction of the substrate as shown in FIG. 6 .
FIGS. 8A to 8D are graphs, respectively, plotting the characteristics of TFTs in which channels are formed in horizontal and vertical directions of a substrate with a crystallized silicon thin film formed therein according to the SLS process of the present invention. In the case of FIGS. 8A to 8D , the measured substrate was a 2-inch low-temperature polysilicon TFT and the thickness of the crystallized polysilicon thin film was about 800 Å.
FIGS. 8A and 8B are graphs plotting the characteristics of N-TFT and P-TFT in which the channels are formed in a horizontal direction of the substrate with the crystallized silicon thin film formed therein by means of the SLS process according to the present invention, respectively; and FIGS. 8C and 8D are graphs plotting the characteristics of N-TFT and P-TFT in which the channels are formed in a vertical direction of the substrate with the crystallized silicon thin film formed therein by means of the SLS process according to the present invention.
Referring to FIGS. 8A to 8D , the characteristics of each of the TFTs, e.g. I on (for Vds=10.1 and Vgs=20) and electron mobility (for Vds=10.1) are shown in the following Table 2.
TABLE 2
N-TFT
P-TFT
Electron
Electron
Mobility
Mobility
I on (μA)
(cm 2 /Vs)
I on (μA)
(cm 2 /Vs)
Direction
1 st
2nd
1st
2nd
1 st
2nd
1st
2nd
Horizontal
750
923
84.27
105.74
918
914
87.02
84.23
Vertical
727
749
84.64
101.56
756
750
61.42
61.46
The I on (μA) and electron mobility (cm 2 /Vs) of the horizontal N-TFT are about 750 to 923 and about 84 to 106, respectively; and the I on (μA) and electron mobility (cm 2 /Vs) of the horizontal P-TFT are about 914 to 918 and about 84 to 87, respectively.
Further, the I on (μA) and electron mobility (cm 2 /Vs) of the vertical N-TFT are about 727 to 749 and about 85 to 102, respectively; and the I on (μA) and electron mobility (cm 2 /Ns) of the vertical P-TFT are about 750 to 756 and about 61, respectively.
With the invention, the number of grain boundaries that extend in the horizontal and vertical directions of the substrate can be minimized, and thus, a difference between the horizontal and vertical characteristics becomes substantially nonexistent. As a result, it is not necessary to consider the directivity of channels when designing TFTs since the limitation associated with the directional anisotropic property of particles has been eliminated. Effectively, a design constraint has been eliminated.
As described above, according to the present invention, the number of grain boundaries in the horizontal and vertical directions of the substrate can be minimized, and there is hardly a difference between the vertical and horizontal characteristics since a crystallized particle is inclined at about 45 degrees even though a grain boundary exists. As a result, the limitation associated with the directional anisotropic property in conventional devices is solved and TFTs can be designed without limitation to the direction of TFT channels when a circuit for an SOG product is built in a panel.
Although the present invention has been described in detail in connection with the specific embodiment of a mask for silicon crystallization, a method for crystallizing silicon using the same and a display device according to the present invention, it will be readily understood by those skilled in the art that various modifications and changes can be made thereto within the technical spirit and scope of the present invention. It is also apparent that the modifications and changes fall within the scope of the present invention defined by the appended claims.
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A mask for silicon crystallization capable of minimizing the number of grain boundaries in crystallized silicon, a method for crystallizing silicon using the mask, and a display device are presented. The mask includes a group of slits that are inclined at a predetermined angle with respect to a scan direction and a group of slits including slits inclined at a predetermined angle with respect to the former group of slits. The groups of slits are separated by an interval along the scan direction, and the substrate and/or mask is moved by the interval between irradiation by laser through the slits. Further, there are provided a method for crystallizing silicon using the mask and a display device. By reducing the number of grain boundaries that extend horizontally or vertically on the substrate, the invention obviates a design limitation associated with the directional anisotropy in sequential lateral solidification (SLS) technique.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application claims priority to U.S. Provisional Patent Application Ser. No. 60/817,675 filed Jun. 30, 2006, the disclosure of which is incorporated herein in its entirety by this reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates generally to devices for removing adhesive and to packaging for storing and dispensing such devices, and more particularly to devices and methods for removing wound closure topical adhesives.
[0004] 2. Background of Related Art
[0005] Biocompatible solvent compositions are known to be used on adhesive articles in order to solubilize the adhesive used in wound closure. For example, it is known to apply a biocompatible solvent composition such as isopropyl alcohol to an adhesive such as cyanoacrylate by various methods such as by spray applicator, a sponge applicator, or a towelette applicator. However, these methods have proved to be inconvenient, time consuming and unsuccessful particularly in difficult to reach or isolated environments.
[0006] Illustratively, it is difficult to apply compositions with low viscosity using conventional devices. If the low viscosity composition is stored in a container, the user will squeeze the container to dispense a quantity of the composition. However, it is difficult to squeeze the container such that the correct amount of the composition is dispensed. It is often the case that the container is squeezed too much and a large quantity of the composition is dispensed. As a result, the composition may flow into areas to which the user did not intend to apply the composition. This results in increased time to effect the removal of the adhesives as well as waste of the solvent product.
[0007] An alternative approach to applying a solvent composition is to initially apply the solvent from a storage container onto an applicator and then onto the target surface. In such an approach, a user squeezes the container, for example, containing the solvent composition so as to apply a portion of the solvent onto the applicator. The applicator is then moved into physical contact with the adhesive so that the adhesive would be solubilized. However, solvents with low viscosity compositions may run off the applicator before it is adjacent the surface.
[0008] If the solvent composition is stored in a bottle, the user inverts the bottle to dispense a quantity of the solvent onto an applicator such as a swab, towelette or sponge applicator. However, inverting a bottle of solvent composition frequently and unpredictably results in dispensing more solvent than is necessary and increases the chances of contaminants to be transferred into the bottle and on the applicator.
[0009] Further, a problem arises if the container of solvent composition is to be used more than once, as is common. If a user chooses to apply the solvent composition directly from the container onto the surface, and not to use an applicator, the dispensing tip may contact the surface upon which the solvent is being applied. Over multiple uses, contaminants may be transferred from one surface to another surface. As is apparent, this is especially of concern with the application of compositions in the medical field.
[0010] Further, there are other problems associated with conventional techniques with the application of solvent compositions in certain environments, particularly ones in which the surface is difficult to reach or is isolated. If a user wishes not to use an applicator, it is necessary for the dispensing tip of the container to be positioned adjacent to or on the surface. However, the container may not easily fit within the spatial constraints in which the surface is located. As a result, the spatial constraints may limit applications using only the container and force a user to use an applicator. This raises a further problem in that an appropriate applicator may not be conveniently available.
[0011] Conventional devices fail to provide an applicator and/or a kit that is optimized for convenient dispensing and application of biocompatible solvent materials for removal of adhesives on a variety of surfaces and structures.
SUMMARY
[0012] Accordingly, an adhesive removing device in accordance with the present disclosure to address the need for an easy to use and efficient package assembly for dispensing and applying an adhesive remover, preferably for wound closure adhesives.
[0013] In one embodiment, the package assembly includes a sterilized enclosure containing a wiping mechanism or applicator with a biocompatible composition embedded in the absorbent portion of a wiping mechanism or applicator, for applying to and removing adhesives. The biocompatible composition includes a solvent and moisturizing agent. The solvent includes, but is not limited to isopropyl alcohol, benzyl alcohol, esters of acetic acid and/or mixtures thereof. The moisturizing agent includes but is not limited to aloe. In some embodiments, the absorbent portion of the applicator is wrapped with a removable plastic layer.
[0014] The disclosure provides an easy and efficient approach to apply these solvents to adhesives. In particular, the disclosure provides a package assembly or kit to hold and apply an adhesive removing device conveniently, inexpensively and effectively.
[0015] In embodiments, the enclosure optionally includes a compartment configured and dimensioned for housing applicators. At least one applicator is contained within the enclosure. In some embodiments, the applicator includes a shaft having two ends and an absorbent portion at one or each end of the shaft. The two absorbent portions may be differently configured for wiping and drying a surface to be treated, and for applying compositions, respectively.
[0016] In another embodiment, the applicators contained within the enclosure comprise at least one absorbent portion on a distal end and on a proximal end of an elongated shaft of the applicator wherein each absorbent portion is individually wrapped with a removable plastic layer.
[0017] In embodiments, the enclosure includes a base portion and a top layer. The base portion comprises a fibrous layer while the top layer comprises a plastic layer. The fibrous layer comprises polyolefin, cellulosic, alginic and polysaccharide fibers while the plastic layer comprises polyethylene.
[0018] In embodiments, the composition material can be sequentially sterilized—e.g., once before being placed on the applicator, after being placed in the enclosure, and optionally after the applicator is placed in the enclosure. In such embodiments, the composition material can be subjected to sequential sterilization procedures with substantially no effect on the effectiveness of the solvent occurring.
[0019] In further embodiments, a method for storing and applying an adhesive remover in accordance with the embodiments above are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Although specific embodiments of the present disclosure will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present disclosure. Various changes and modifications obvious to one skilled in the art to which the present disclosure pertains are deemed to be within the spirit, scope and contemplation of the present disclosure as further defined in the appended claims.
[0021] FIG. 1 is a top plan view of an enclosure of the package assembly or kit in accordance with the embodiments of the present disclosure;
[0022] FIG. 2 is a perspective view showing an applicator in accordance with the embodiments of the present disclosure; and
[0023] FIG. 3 is a side elevation view of an enclosure and applicator in accordance with the embodiments of the present disclosure.
DETAILED DESCRIPTION
[0024] In general, the present disclosure is directed to an adhesive removing device and package assembly or kit which includes, a wiping mechanism with a biocompatible solvent composition embedded in an absorbent portion of the wiping mechanism therein. The package assembly according to the present disclosure can be used in conjunction with a wide variety of applications of biocompatible solvent composition materials, wherein it is necessary or desirable to efficiently and easily remove an adhesive material. Examples include, but are not limited to, those applicable to medical, industrial, and home use. For example, the package assembly in accordance with the present disclosure may be used to apply a composition of solvent and moisturizing agent, for the removal of wound closure adhesives such as those used for surgically incised or traumatically lacerated tissues; retarding blood flow from wounds; dressing burns; dressing skin or treating stomatitis or other superficial or surface sores or wounds.
[0025] The package assembly may be used to store and apply a wide variety of solvents, including but not limited to: isopropyl alcohol, benzyl alcohol, esters of acetic acid and/or mixtures thereof. The package assembly may be used on a number of different adhesives including polymerizable liquid adhesives such as 1,1-disubstituted ethylene monomers and polymers, including cyanoacrylate monomers such as the alpha-cyanoacrylates.
[0026] One particular application of the package assembly of the present disclosure is in conjunction with the storage and application of a composition comprising a solvent material and a moisturizing agent for medical or surgical procedures. It should be appreciated that any known or later developed solvent for removing adhesive materials or any later developed moisturizing agents can be used in conjunction with this disclosure.
[0027] The presently disclosed adhesive removing device and kit will be further described in conjunction with the accompanying figures showing exemplary embodiments of the present disclosure. In the figures, like numerals have been used to identify like components.
[0028] FIG. 1 shows an enclosure 100 of a package assembly or kit in accordance with an embodiment of the present disclosure to hold and apply an adhesive removing device conveniently, inexpensively and effectively. The enclosure 100 contains a base portion 104 and a top layer 108 sealed along the edges and having one peelable flap 106 along one edge wherein the user may easily remove the top layer from the base portion. The enclosure 100 may include a cavity or compartment 102 which is configured and dimensioned to hold at least one applicator 210 (see FIG. 2 ). The enclosure 100 may be any of a variety of shapes and designs dependent on numerous factors including, for example, the specific contents of the enclosure and the intended use of the adhesive removing device contained within the enclosure.
[0029] Referring to FIG. 2 , the applicator 210 includes at least one absorbent portion 212 a at a distal end of an elongated shaft 220 and at least one absorbent portion 212 b on a proximal end of elongated shaft 220 .
[0030] The applicator 210 may be formed of any of a wide variety of materials including but not limited to polymerized materials such as plastics, foams, rubbers, thermoplastics, thermosets, metals, for example, or any other suitable material. Further, it should be recognized that the applicator according to the other embodiments of the present disclosure, as described herein, may also be constructed of hydrophilic polyurethane foam. In general, the only limitation on the materials used to fabricate them is that the material must be sufficiently compatible with the composition to be dispensed therein that undesirable effects on the composition do not occur during contact of the composition with the enclosure 100 .
[0031] The absorbent portion 212 may be constructed of any suitable hydrophilic material such as a cotton swab or fibrous pad material, for example. The material, such as cotton, forming the absorbent portion 212 of the applicator 210 can absorb a composition, such as various solvent compositions. The absorbed composition can then be applied to a surface, such as a wound closure adhesive.
[0032] In one embodiment, an applicator 210 may have at least one absorbent portion 212 a or 212 b with a composition embedded therein and further wrapped with a layer of polymeric material 216 or 218 . The polymeric material layer 216 or 218 increases the effectiveness of sterility of the applicator as well as eliminates the chances of altering the opposite absorbent portion's function.
[0033] Furthermore, the material layer can be formed of polymeric materials that have been modified by a post-halogenation treatment to be highly resistant to attack, solvation and/or permeation and thus provide an extended shelf life of the containers and biocompatible compositions.
[0034] Now referring to FIG. 3 , an applicator 330 is illustrated removed from enclosure 300 in accordance with embodiments of the present disclosure. The applicator 330 includes a first absorbent end 312 a and a second absorbent end 312 b . The absorbent end 312 a in FIG. 3 is tapered such that the tip of the absorbent end 312 a is wider in dimension than the base. The dimensions of the applicator 330 allow the applicator to be used to apply adhesive remover in a variety of environments and spatial constraints. The wider end of the applicator in the embodiment of FIG. 3 is useful when the surface to be treated needs to be dried after the solvent composition is applied to the adhesive and dissolves the adhesive.
[0035] However, it should be recognized that the applicator 330 shown in FIG. 3 is only illustrative and not limiting. For example, the applicator may include only one absorbent end. Further, the absorbent end or ends of the applicator may be a wide variety of shapes and sizes such as circular, elliptical, elongated, curved or square depending on the particular area where the adhesive needs to be removed. Also, in alternative illustrative embodiments, the absorbent end could be in the form of a brush, sponge or constructed of foam.
[0036] Still referring to FIG. 3 , enclosure 300 includes a base portion 304 and a top layer 302 . The top layer 302 may be removably attached to the base 304 . However, it should be recognized that in accordance with the present disclosure the interrelationship of the base 304 and the top layer 302 is not limited to the arrangement shown in FIG. 3 ., but rather may be a wide variety of shapes and designs.
[0037] When a user wants to apply the adhesive removing device to an adhesive wound closure, for example, the user opens the enclosure 300 via the peelable flap 302 and removes an applicator 330 from the enclosure 300 . Then, the absorbent portion 312 a or 312 b is used to make physical contact with the surface upon which the adhesive is to be removed.
[0038] It will be understood that a UV stabilizing agent may be included in any of the enclosures for applicators described herein to provide the UV stabilization and protection functions to the enclosures and protect the materials of the applicators from degradation due to exposure to UV radiation.
[0039] The enclosure 300 , can be any conventional enclosure or pouch used for medical devices manufactured from any suitable material known to those skilled in the art. In one illustrative embodiment, enclosure 300 is formed by heat sealing two panels of aluminum foil coated on the interior surfaces thereof with a heat sealable polymeric composition. Other means for sealing the enclosure may be employed as are well known to those skilled in the art.
[0040] In another embodiment, enclosure 300 may be formed from a hydrophobic material. The term “hydrophobic”, as described herein, refers to materials that are not normally water soluble and absorb relatively low amounts of water, i.e., less than about 10% by weight. Some examples of these materials include, but are not limited to, polymers, copolymers, homopolymers, and block copolymers formed from monomers such as ε-caprolactone, glycolide, 1-lactide, d,1-lactide, d-lactide, meso-lactide, trimethylene carbonate, 4,4-dimethyl-1,3-dioxan-2-one, p-dioxanone, dioxepanone, δ-valerolactone, β-butyrolactone, ε-decalactone, 2,5-diketomorpholine, pivalolactone, α,α-diethylpropiolactone, 6,8-dioxabicyclooctan-7-one, ethylene carbonate, ethylene oxalate, 3-methyl-1,4-dioxane-2,5-dione, 3,3-dimethyl-1,4-dioxane-2,5-dione, and other substituted glycolides, and substituted lactides. Some additionally useful hydrophobic materials include polyolefins (i.e. Tyvek.®) and polysiloxanes.
[0041] In another embodiment, enclosure 300 may be formed from a hydrophilic material. The term “hydrophilic”, as described herein, refers to materials that are normally water soluble and absorb relatively high amounts of water. Some examples of these materials include, but are not limited to, polyalkylene glycols, such as polyethylene glycol, polyacrylates such as polymers of methacrylates and 2-hydroxyethyl methylacrylate, aminoalkyl acrylates, such as N,N-dimethylacrylamide, polyvinylalcohols, polyvinylpyrrolidones, polyoxyethylenes, polyacrylamides, poly(2-hydroxy-ethylmethacrylate), polymethacrylamide, dextran, alginic acid, sodium alginate, polysaccharides, gelatine and copolymers of two or more of the monomers from which the above polymers are derived and polyoxyethylene/polyoxypropylene block copolymers.
[0042] In still another embodiment, enclosure 300 can be made of a combination of hydrophobic and hydrophilic materials. An example of an enclosure with a combination of hydrophobic and hydrophilic materials can include a polyolefin sheet (i.e. Tyvek.®) and a polyethylene sheet adhered together with a release agent.
[0043] The base 304 is elongated and includes at least one cavity 322 or 324 formed within. Specifically, the base 304 includes a cavity for at least one applicator 330 . The applicator cavity 326 is formed in the shape of an elongated slot and extends along the length of the base 304 . However, the present disclosure is not limited to one applicator cavity 326 . For example, a single cavity might be provided, in which a plurality of applicators are positioned side by side for additional uses. In alternative embodiments, a plurality of applicators may be positioned in a single enclosure or may be disposed individually in separate enclosures.
[0044] Alternatively or in addition, the adhesive removing composition may contain preservatives and/or stabilizers to counteract effects of minor amounts of such contaminants.
[0045] The adhesive removing composition includes a suitable solvent for removing adhesive from the surface of skin and/or wound closure. Suitable solvents include but are not limited to, glycols, such as ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, polyethylene glycol, and polypropylene glycol; glycol ethers; alcohols, such as methanol, ethanol, propanol, phenethyl alcohol and phenoxypropanol; ketones, such as acetone and methyl ethyl ketone; esters, such as ethyl acetate, butyl acetate, triacetyl citrate, and glycerol triacetate; carbonates, such as propylene carbonate and dimethyl carbonate; and mixtures thereof. It is preferred that the solvent is selected from water, glycols, glycol ethers, esters and mixtures thereof.
[0046] The adhesive removing composition may also contain suitable bioactive materials which include, but are not limited to, medicaments such as antibiotics, antimicrobials, antiseptics, bacteriocins, bacteriostats, disinfectants, steroids, anesthetics, fungicides, anti-inflammatory agents, antibacterial agents, antiviral agents, antitumor agents, growth promoting substances, moisturizing components, antioxidants, tackifiers, solubilizers, colorants, perfumes, surfactants, UV absorbers, inorganic fillers and pH adjusting agents or mixtures thereof.
[0047] Preferable medicaments are those that are anions or help in radical generation or that are ion pairs or are themselves radicals. In embodiments, the medicament includes, but is not limited to a quaternary ammonium halide such as alkylbenzyldimethylammonium chloride (benzalkonium chloride; BAC) with an alkyl containing 6-18 carbon atoms, its pure components, or mixtures thereof, or benzethonium chloride; or a salt of sulfadiazine, such as a silver, sodium, or zinc salt, water-soluble placenta extract, allantoin, lecithin, amino acids, kojic acid, proteins, saccharides, hormones, placenta extract, components extracted from various types of herbal medicine such as aloe, sponge gourd and liquorice, vitamin A, vitamin C, vitamin D, vitamin E and other vitamins, etc. or mixtures thereof.
[0048] With regard to the moisturizing components, an aqueous solution of succinylkefiran, an aqueous solution of acetylkefiran, an aqueous solution of maleylkefiran, malt sprout extract, Rosae fructus extract, orange extract, orange fruit juice, raspberry extract, kiwi extract, cucumber extract, gardenia extract, grapefruit extract, Crataegus cuneata extract, xanthoxylum extract, Crataegus oxycantha extract, Juniperus communis extract, Zizyphi fructus extract, Ziziphus jujuba extract, duke extract, tomato extract, grape extract, sponge gourd extract, lime fruit juice, apple extract, apple fruit juice, lemon extract, lemon fruit juice, etc. can be added singly or in combinations of two or more types.
[0049] With regard to the antioxidants, ascorbic acid, propyl gallate, butyl hydroxyanisole, dibutyl hydroxytoluene, nordihydroguairetic acid, tocopherol, tocopherol acetate, etc. or mixtures thereof can be added.
[0050] With regard to the tackifiers, casein, pullulan, agar, dextran, sodium alginate, soluble starch, carboxy starch, dextrin, carboxymethyl cellulose, sodium carboxymethyl cellulose, methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, polyvinyl alcohol, polyethylene oxide, polyacrylamide, polyacrylic acid, polyvinylpyrrolidone, carboxyvinyl polymer, polyvinyl ether, methyl vinyl ether-maleic anhydride copolymer, isobutylene-maleic anhydride copolymer, polyethyleneimine, etc. can be added.
[0051] With regard to the solubilizers, benzyl alcohol, pyrrothiodecane, peppermint oil, isopropyl myristate, crotamiton, etc. or mixtures thereof can be added.
[0052] With regard to the colorants, those that can have a large influence on the image of the preparation and contribute to an improvement in the user's feeling during use and a feeling of skin revitalization are preferred, for example, approved colorants such as Red No. 2 (amaranth), Red No. 3 (erythrosine), Red No. 102 (new coccine), Red No. 104 (1) (phloxine B), Red No. 105 (1) (rose bengal), Red No. 106 (acid red), Yellow No. 4 (tartrazine), Yellow No. 5 (sunset yellow FCF), Green No. 3 (fast green FCF), Blue No. 1 (brilliant blue FCF) and Blue No. 2 (indigo carmine) or mixtures thereof can be added, but they are not particularly limited thereby.
[0053] With regard to the surfactants, anionic surfactants such as sodium dioctylsulfosuccinate, alkylsulfate salts, 2-ethylhexylalkylsulfate ester sodium salt and sodium n-dodecylbenzenesulfonate, cationic surfactants such as hexadecyltrimethylammonium chloride, octadecyldimethylbenzylammonium chloride and polyoxyethylenedodecylmonomethylammonium chloride, nonionic surfactants such as polyoxyethylene stearyl ether, polyoxyethylene tridecyl ether, polyoxyethylene nonyl phenyl ether, polyoxyethylene octyl phenyl ether, polyoxyethylene monostearate, sorbitan monostearate, sorbitan monopalmitate, sorbitan sesquioleate, polyoxyethylene sorbitan monolaurate, polyoxyethylene sorbitan monooleate, glycerol monostearate, polyglycerol fatty acid esters and polyoxyethylene octadecylamine can be added.
[0054] With regard to the UV absorbers, p-aminobenzoic acid, p-aminobenzoate esters, amyl p-dimethylaminobenzoate, salicylate esters, menthyl anthranilate, umbelliferone, esculin, benzyl cinnamate, cinoxate, guaiazulene, urocanic acid, 2-(2-hydroxy-5-methylphenyl)benzotriazole, 4-methoxybenzophenone, 2-hydroxy-4-methoxybenzophenone, dioxybenzone, octabenzone, dihydroxydimethoxybenzophenone, sulisobenzone, benzoresorcinol, octyldimethyl p-aminobenzoate, ethylhexyl p-methoxy cinnamate, etc. or mixtures thereof can be added.
[0055] With regard to the inorganic fillers, titanium oxide, talc, zinc oxide, hydrated silica, magnesium carbonate, calcium hydrogenphosphate, magnesium silicate, diatomaceous earth, silicic anhydride, bentonite, etc. or mixtures thereof can be added.
[0056] With regard to the pH adjusting agents, acetic acid, formic acid, lactic acid, tartaric acid, oxalic acid, benzoic acid, glycolic acid, malic acid, citric acid, hydrochloric acid, nitric acid, sulfuric acid, sodium hydroxide, potassium hydroxide, methylamine, ethylamine, propylamine, dimethylamine, diethylamine, dipropylamine, trimethylamine, triethylamine, tripropylamine, monoethanolamine, monoethanolamine, monopropanolamine, dimethanolamine, diethanolamine, dipropanolamine, trimethanolamine, triethanolamine, tripropanolamine, etc., or mixtures thereof can be added.
[0057] Another optional ingredient is selected from essential fatty acids (EFAs), i.e., those fatty acids which are essential for the plasma membrane formation of all cells, in keratinocytes EFA deficiency makes cells hyperproliferative. Supplementation of EFA corrects this. EFAs also enhance lipid biosynthesis of epidermis and provide lipids for the barrier formation of the epidermis. The essential fatty acids are preferably chosen from linoleic acid, Y-linolenic acid, homo-Y-linolenic acid, columbinic acid, eicosa-(n-6,9,13)-trienoic acid, arachidonic acid, Y-linolenic acid, timnodonic acid, hexanoic acid and mixtures thereof.
[0058] Antimicrobial and antifungal actives can be effective to prevent the proliferation and growth of bacteria and fungi. Non-limiting examples of antimicrobial and antifungal actives include antibiotic drugs, quaternary ammonium compounds such as benzalkonium chloride; benzethonium chloride; triclosan; triclocarban; and mixtures thereof and the like. Anti-wrinkle, anti-skin atrophy and skin repair actives can be effective in replenishing or rejuvenating the epidermal layer. These actives generally provide these desirable skin care benefits by promoting or maintaining the natural process of desquamation. Non-limiting examples of anti-wrinkle and anti-skin atrophy actives include retinoic acid and its derivatives, and the like. Skin barrier repair actives are those skin care actives which can help repair and replenish the natural moisture barrier function of the epidermis. Non-steroidal cosmetic soothing actives can be effective in preventing or treating inflammation of the skin. The soothing active enhances the skin appearance benefits of the present disclosure, e.g., such agents contribute to a more uniform and acceptable skin tone or color. Benefit agents in the present disclosure may also include anti-itch ingredients. Suitable examples of anti-itch ingredients which are useful in the compositions of the present disclosure include hydrocortisone, and the like.
[0059] The adhesive removing solution of the present disclosure is formulated with the above described components of solvent and moisturizing agents as the essential ingredients. The contents of the moisturizing agent component in the remover solution should be in the ranges from 0.01% to 10% by weight and from 0.1% to 30% by weight, respectively, or, preferably, in the ranges from 0.1% to 5% by weight and from 0.5% to 10% by weight, respectively, the balance to 100% by weight being the solvent component and optionally, water.
[0060] According to this disclosure, in some embodiments, the adhesive removing composition and other components of the package assembly or kit may be sterilized. For example, the enclosure containing the applicator 330 containing the adhesive removing composition embedded therein shown in FIG. 3 may be sterilized. The enclosure 300 may be sterilized by the same or a different method as that used for the adhesive removing composition or applicator 330 . Also, the enclosure 100 , illustrated in FIG. 1 , may be sterilized together with the applicator 210 enclosed therein.
[0061] Various sterilization processes may be used for the separate components of the package assembly or kit. Examples include, but are not limited to, chemical sterilization (e.g., exposure to ethylene oxide or hydrogen peroxide vapor), physical sterilization (e.g., dry or moist heat) or other techniques such as microwave irradiation, gamma radiation, ionizing radiation, and electron beam irradiation. It will be understood that the same or different sterilization technique may be used to sterilize different components of the package assembly.
[0062] However, in embodiments in which the enclosure 100 is formed of a non-air permeable material such as a plastics material, the enclosure may also be sterilized. Further, in some embodiments, a non-air permeable material, such as a plastics material, may be applied over an air permeable material such as a paper material. For example, a plastics material may be applied to a cardboard enclosure by a shrink wrapping process. In such embodiments, after applying the plastics material or the like over the enclosure, the package assembly may be sterilized.
[0063] According to illustrative embodiments of the present disclosure, sequential sterilization can be performed with substantially no resulting change to the adhesive removing composition. Accordingly, the sterilized adhesive compositions can have a satisfactory shelf life.
[0064] While the present disclosure presents specific embodiments outlined above, it is evident that many alternatives, modifications and variations may be apparent to those skilled in the art. For example, various different combinations, and shapes, sizes and arrangements, of the described features are contemplated. Accordingly, the embodiments of the present disclosure as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure.
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A kit for storing and applying an adhesive removing device comprising an enclosure which includes a base portion and a removable top layer releasably secured to the base portion; an adhesive removing device including at least one wiping mechanism which includes at least one absorbent portion; and a biocompatible composition including a solvent and a moisturizing agent embedded in the absorbent portion of the wiping mechanism. A method for storing and applying an adhesive removing device comprises a series of steps for using the adhesive removing device to remove an adhesive from a surface.
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CROSS-REFERENCE TO RELATED APPLICATION
The application claims priority from co-pending provisional application No. 60/062,479, filed Oct. 17, 1997, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention is directed to a dental applicator for applying amalgam or other filling material to teeth. More particularly, the present invention is directed to a dental applicator which can be repeatedly used without any danger of permanent clogging by hardened amalgam or filling material and which, in a preferred embodiment, comprises an amalgam dispenser which can be removed from a handle, e.g., for cleaning, replacement or alternative size combinations.
Various types of lever-activated dental amalgam applicators are known, as exemplified by U.S. Pat. No. 5,580,245 to Nevin, U.S. Pat. No. 4,355,976 to Bemer, U.S. Pat. No. 4,273,534 to Seid, U.S. Pat. No. 4,306,864 to Law et al., U.S. Pat. No. 4,673,353 to Nevin and U.S. Pat. No. 3,735,492 to Karter et al. For example, U.S. Pat. No. 4,673,3 53 to Nevin discloses a lever-operated applicator 10 for a light-curable dental composition in which a hollow receptacle 50 is coupled to the lever 30 and elevated by depressing the lever arm 34 (column 3, lines 47-54). The receptacle is formed from inert metal or opaque plastic (column 3, lines 58-59) while the plunger 18 which extends through the receptacle cavity can be made of any conventional clear plastic such as methacrylic acid and polymer, methylmethacrylate polymer, polycarbonate or polystyrene (column 3, lines 64-67). Preferably, a clear solid plastic core 60 forming plunger 18 is surrounded by an inert metal or plastic coating (column 3, lines 67-column 4, line 17). U.S. Pat. No. 4,273,534 to Seid discloses an amalgam carrier and dispenser having a terminal end surface 16 of a plunger 10 formed of especially hard metallic material to resist abrasion effect.
Solidificator and clogging of amalgam in the receptacle or barrel of such lever-actuated dental amalgam applicators has been a significant problem encountered by dentists. Generally, amalgam is applied onto a tooth while at room temperature, e.g., about 68° F. to about 70° F., i.e., while in malleable condition. However, because amalgam is administered under ambient temperature of about 75-80° F. (or even cooler if a dental office is air conditioned), amalgam begins to solidify immediately upon receipt within the lever-actuated barrel. Therefore, after repeated application, solidified amalgam builds upon interior surfaces of the cylindrical barrel, interfering with proper administration of amalgam filling into a tooth. Eventually, the entire barrel becomes totally clogged with solidified amalgam so that the entire amalgam applicator is rendered useless and must be discarded, handle and all.
Attempts have been made to create amalgam applicators with removable tips, e.g., U.S. Pat. No. 3,735,492 to Karter et al., so that once a tip becomes clogged, it can be removed from the amalgam carrier and replaced by a clean tip. However, such previous designs have proven cumbersome if not totally difficult to implement and furthermore do not solve the problem of initially preventing amalgam from adhering inside the lever-activated barrel.
Accordingly, it is an object of the present invention to improve dispensing and dispersing of dental amalgam or other filling material onto a tooth.
It is a more specific object of the present invention to inhibit or totally prevent accumulation of hardened amalgam or filling material within a lever-activated barrel of a dental amalgam carrier upon repeated actuation.
It is a further object of the present invention to provide a dental amalgam or filling applicator which can be effectively cleaned and re-used and/or having individual parts thereof which can be cleaned and re-used, such as a separable amalgam carrier and handle.
Further objects of the present invention will become apparent from the description herein.
SUMMARY OF THE INVENTION
These and other objects are attained by the present invention which is directed to a dental applicator for dispensing amalgam and other filling material such as condensable resin or composite resin and comprising a barrel and a plunger arranged to reciprocate into and out of the barrel. The barrel and/or plunger are fabricated from plastic or metal/metallic material provided with a coating thereon. In a preferred embodiment, the applicator is lever-activated, i.e., by pivotally mounting the barrel to reciprocate the same by pressing and releasing a lever.
The applicator of the present invention permits dental amalgam or other filling material to be reliably dispensed therefrom over repeated usage, and with minimal clogging/solidification of amalgam or filling residue within the barrel. Additionally, because of the particular combination of plastic and coated metal/metallic material for the plunger and barrel, it is extremely easy to remove the amalgam from the applicator, e.g., by brushing and/or sterilizing the components. For example, unwanted amalgam residue can simply be removed by wiping the applicator with a cotton swab dabbed with isopropyl alcohol. Furthermore, in a preferred embodiment, the applicator tip, including the lever-activated barrel and plunger, can be removed from the handle for cleaning and immediately substituted with a new applicator tip which can be easily secured to the handle for appropriate use.
When the inventive applicator is used to dispense condensable resin, any metallic streaking upon the dispensed resin is automatically eliminated, thus both improving dispensing and preventing unwanted contamination of the ultimate filling material.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in further detail with reference to the accompanying drawings, in which:
FIG. 1 is a right elevational view of a dental applicator in accordance with the present invention;
FIG. 2 is a sectional view of a front end portion of the applicator shown in FIG. 1;
FIG. 3 is a schematic sectional view, similar to FIG. 2, and illustrating operation of the dental applicator in accordance with the present invention;
FIG. 4 is an exploded view of the dental applicator shown in FIG. 1 and illustrating assembly of the various component parts;
FIG. 5 is a schematic perspective view illustrating assembly of one embodiment of the dental applicator in accordance with the present invention;
FIG. 6 is a schematic perspective view, similar to FIG. 5, and illustrating assembly of another embodiment of the dental applicator in accordance with the present invention;
FIG. 7 is an elevational view illustrating the pertinent portion of an assembled, coupled dental applicator in accordance with the present invention;
FIG. 8 is a sectional view of FIG. 7; and
FIGS. 9-11 are schematic views illustrating coupling and assembly of other embodiments of a dental applicator in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will be made to the accompanying drawings in which similar components are denoted with prime (') symbols.
As illustrated in the figures, e.g., FIGS. 1-4, the dental applicator 10 of the present invention comprises a handle 5, a plunger or hook 1 mounted upon the handle 5 and a barrel 3 pivotally mounted upon the plunger 1. More particularly, plunger 1 is fixed upon base 4 which is, in turn, removably mounted upon handle 5 as illustrated in FIG. 4 and as described further infra.
The barrel 3 is pivotally mounted upon the base 4 through a lever 6 and spring 7, such as a leaf spring. In the illustrated embodiment, the barrel 3 is manufactured from plastic while the plunger 1 is manufactured from metal or metallic material 8 and provided with a separate coating 9. The combination of a plastic barrel 3 with a coated metal/metallic plunger, has proven quite effective in inhibiting and even totally preventing accumulation of solidified amalgam/filling material residue within the barrel 3 upon repeated applications by a dentist. It is pointed out that the entire plunger 1 is coated, not just the tip portion thereof contacting a tooth surface, thus preventing unwanted adherence of amalgam over the entire surface thereof, especially the portion extending through the barrel 3. At the same time, ejection/administration of the entire amalgam content contained within the barrel 3 is ensured; in this regard, provision of the plastic barrel 3 in combination with the coated 9 metal/metallic plunger 8 does not sacrifice touch and control by a dentist, critical for proper lever actuation and administration of amalgam.
In other words, a dentist who has been previously trained, e.g., with an all metal applicator comprising both a metal barrel and metal plunger (conventionally available in the art) or even an applicator comprising a plastic barrel about a metal plunger, can immediately adapt to handling the inventive applicator 10 without any loss of dexterity, control, reliance and will thereby be assured of reliably administering the precise dose of amalgam contained within the barrel 3. This control of amalgam application is extremely important to a dentist and cannot be minimized. This is one reason why dentists who are trained with syringe-type applicators never adapt or switch to using lever-type applicators as illustrated herein and vice versa.
While the present invention has been illustrated with a lever-actuated 6 applicator 10 herein, it is also contemplated to practice the present invention with a syringe-type actuated applicator as disclosed, e.g., in U.S. Pat. No. 2,903,794 to Carfagni, in which case the plunger 28 and the outer barrel-like tip 12 are constructed as described supra. Furthermore, although the respective figures illustrate the barrel 3 formed of plastic and the plunger 1 of coated 9 metal 8, it is within the contemplation of the present invention to form the plunger 1, or at least the tip portion 2 thereof, entirely of plastic material and the barrel 3 of coated metal/metallic material. Moreover, both the plunger 2 and barrel 3 can be formed entirely of certain plastic material, or alternatively, both the plunger 2 and barrel 3 can both be formed of metal/metallic material coated with certain material, within the contemplation of the present invention.
The plastic used to fabricate the barrel 3 should be approved by the Food and Drug Administration (F.D.A.) as Food compliant. Suitable plastics are enumerated, e.g., at 21 C.F.R. §177(a) pp. 204-205, the contents of which are incorporated by reference herein. More particularly, the plastic can be suitable homopolymers, copolymers or terpolymers any of acceptable polyethylenes, polypropylenes, polymethacrylates, derivatives of any of the foregoing, or mixtures thereof. Especially preferred plastics include:
DELRIN, a crystalline thermoplastic polyacetal resin, available from E.I. Du Pont de Nemours & Co., Inc., Wilmington, Del.;
TEFLON, (polytetrafluoroethylene), also available from Du Pont;
RADEL, a polysulfone resin available from Union Carbide Corp., Ridgefield, Conn.;
NYLON (polyamide) also available from Du Pont;
NYLON 6 (linear polymer obtained by polymerizing ε-caprolactam), also available from Du Pont; and
ULTEM (polyetherimide) available from General Electric Co., Fairfield, Conn.
The plunger 1 itself, and the handle 5, can both be manufactured from a stainless steel substrate, e.g., from Stainless Steel 300 series available from Ulbrich Stainless, North Haven, Conn. Additionally, the plunger 1 is coated with a coating 9 as enumerated, e.g., in 21 C.F.R. §175.300 such as
Teflon 959-203 (FDA compliant) available from Du Pont,
Xylan 8110-1879 black (FDA compliant) a food grade version of a polytetrafluorethylene-based industrial coating available from Whitford Corporation, Frazer, Pa., and
NEDOX synergistic coating (an electroless nickel coating with fluorocarbon impregnation) and titanium nitride coating, both available from General Magnaplate, Linden, N.J. All these coatings are F.D.A. compliant. Additionally, F.D.A. compliant chromium coating available as Medicos 2000 from the Electrolizing Corporation of Ohio, Cleveland, Ohio, and carbon-based coating available as Diamonex DLC from Diamonex Performance Products, Allentown, Pa., can be utilized in accordance with the present invention.
Conversely, the plunger 1 can be fabricated from any of the above-mentioned plastics while the barrel 3 can be fabricated from stainless steel or similar metal and coated with any of the above-enumerated coatings. Furthermore, instead of metallic material, the plunger 1 or barrel 3 can be manufactured from a ceramic base in turn coated with any of the above-enumerated coatings. One such suitable ceramic is available from Coors Ceramics, Golden, Colo.
The component manufactured from plastic can be injection molded while the component of metal or ceramic can be coated by being dipped in an appropriately heated bath of coating material 9. The bath of coating material 9 can be heated to appropriate temperature which liquefies the coating which will then solidify upon cooling. Additionally, the resulting components can be easily sterilized without danger of softening. For example, TEFLON can be heated to a temperature of about 500° F. without softening while DELRIN can be heated up to about 250° F. without softening. Additionally, Diamonex can be heated to a temperature range of 750-900° F. without softening, while Xylan can be heated to a temperature of about 500° F. without softening. An additional advantage provided by the inventive applicator is that the various components can be easily size-colored. Previously, dentists had to use small silicone bands around the end of a handle as size indicators. The present invention will eliminate need for using such bands which can become separated, by providing automatic color coding based upon size, i.e., different color plastic/coating can be used for different sizes. The combination of components as set forth herein possesses sufficient lubricity to prevent amalgam from adhering while at the same time, possessing sufficient hardness so that a dentist's control is not sacrificed and the overall applicator can be sterilized in an autoclave without damage.
In a preferred embodiment, a plunger tip 2 of Stainless Steel 302 and coated with Teflon, possesses a Knoop coating hardness (10 gram load) of about 20.5 HK 10 for an average of 5 readings with 0.081 inch test wire and about 17.2 HK 10 for an average of 5 readings with a 0.110 inch test wire (testing carried out according to ASTM E-384-89). Accordingly, a coated 9 plunger 1 in accordance with the present invention should possess a Knoop hardness HK 10 of about 15-21, preferably about 17-20. The plunger 1 preferably possesses a coating 9 hardness on the Shore A scale of approximately 95 to 100. The plunger tip, in particular, possesses a coating hardness softer and below the Rockwell C hardness scale.
As a result of the inventive combination of plunger 1 and barrel 3, the inventive applicator 10 can be manufactured with fairly tight tolerances without any danger of abrading or damaging the inner surface of barrel 3 or outer surface and tip 2 of plunger 1. At the same time, provision of such tight tolerances helps prevent amalgam residue from "crawling up" the barrel 3 inner surface and then adhering to the barrel 3 and/or plunger 1. For example, the inner diameter of plastic barrel 3 can be approximately 0.080 inches while the outer diameter of coated plunger 1 can be about 0.0795 inches, providing a tolerance range radius of about 0.0005 inches, comparatively small when compared to prior art dental applicators. In this regard, the thickness of the coating is approximately 0.0004-0.0008 inches, with a thickness of about 0.0005 inches being most preferred. However, various sizes of barrel and plunger, e.g., four various complementary sizes, are provided for in the present invention.
The components forming the lever 6, barrel 3 and plunger 1 of the inventive applicator 10 can be permanently affixed to a handle 5 as with prior art applicators. However, it is also possible within the present invention to provide a dental applicator 10 in which the lever 6, barrel 3 and plunger 1 components are removably mounted upon the handle 3 as illustrated, e.g., in FIGS. 1-4. More particularly, as illustrated in FIGS. 1-4, a base 4 is provided with a channel 11 shaped to receive an extended straight end 12 of hook-shaped plunger 1 which is secured therein by a rivet or nut bolt 13. The leaf spring 7 is concentrically mounted about a neck of the base 4 by means of a collar 14, with an opposite end 15 of spring 7 hooking onto an opening 16 in lever 6 as illustrated in FIGS. 2 and 3. The barrel 3 itself comprises a recess 17 between two adjacent collars and into which a curved end 18 of lever 6 is received as illustrated.
The various component parts forming the pivotally mounted lever 6 and barrel 3 about the plunger, are assembled upon base 4 in the manner illustrated in FIG. 4. The base 4, which can be constructed of stainless steel or other metal/metallic material, ceramic material or of plastic material similar to barrel 3 described supra, is removably mounted in the interior hollow of handle 5 as illustrated in FIGS. 2-4. More particularly, a diametrical bar 20 is mounted across the interior hollow 19 of handle 5 as illustrated; base 4 terminates in an end shaped as a prong 21 and defining a recess 22 substantially complementary to bar 20.
The base 4 is also provided with an extension 23 upon which prong 21 is formed and which comprises an outer diameter substantially complementary to the interior diameter of handle 5. Collar 24 of base 4 is substantially equal in diameter to the outer diameter of handle 5. Therefore, when the base 4 and handle 5 are coupled together in the direction shown in FIG. 4, a force fit or snap fit is created so that base 4 together with all coupled components of the lever-actuated barrel and plunger mechanism are securely and reliably retained upon handle 5 as shown in FIG. 5. At the same time, base 4 and handle 5 can be easily uncoupled from one another by simple movement in opposite directions away from one another as shown in FIG. 5.
FIGS. 6-11 illustrate various alternative embodiments for coupling base 4 and handle 5 together. In FIG. 6, base 4' and handle 5' are provided with complementary male and female members in the shape of a cross. The other features of handle 5' and base 4' remain identical to handle 5 and base 4 shown in FIGS. 1-5. In the embodiment illustrated in FIGS. 7 and 8, an end of handle 5' is provided with external threads 28 while a nut 27 comprising complementary internal threads is mounted upon collar 24' of base 4". This coupling feature shown in FIGS. 7 and 8 can be combined with any of the other coupling features shown in FIGS. 1-6 described supra or FIGS. 9-11 described infra.
In the embodiment shown in FIG. 9, prong 21 has been manufactured of resilient material comprising projections 31 and 32 shaped to respectively seat in annular grooves 29 and 30 of handle 5'". In FIGS. 10 and 11, prong 21" has been provided with slightly altered projections 34 (also resiliently biased) and with handle 5'" provided with differentially-shaped annular grooves 33 to accept projections 34. The operation of coupling the embodiment shown in FIG. 9 is identical to the coupling illustrated in FIGS. 10 and 11; to uncouple either of these two applicator tips, a sharp instrument is inserted into grooves 33 (FIG. 11) or 29 to bias prongs 21" or 21' together and thereby permit the respective base and handle to be moved apart.
The present invention can be applied to an amalgam dispenser having dispensing rods at opposite ends as shown, e.g., in U.S. Pat. No. 4,306,864 to Law et al.
The preceding description of the present invention is merely exemplary and is not intended to limit the scope thereof.
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A dental applicator for applying amalgam or other filling material to a tooth is provided, in which a plunger is arranged to reciprocate into and out of a barrel to thereby eject and administer the amalgam or filling material. The barrel and/or plunger are fabricated from plastic and/or metal or metallic material provided with a coating, to inhibit or totally prevent amalgam residue from solidifying and adhering to the barrel or plunger.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation application of application Ser. No. 08/714,583, filed on Sep. 16, 1996, now U.S. Pat. No. 6,272,457 which is hereby incorporated herein by reference and a claim to priority is made hereby.
FIELD OF THE INVENTION
This invention relates to methods for combining Global Positioning System (“GPS”), Speech Recognition, Radio Frequency (“RF”), and Geographic Information System (“GIS”) to perform mobile field data collection and automatic population of a GIS database with fully attributed and correlated observation data. The system relates particularly to a field data capture system and automatic GIS database population tool for a user to build GIS layers and fully exploit the data in the GIS.
BACKGROUND OF THE INVENTION
Organizations responsible for the maintenance and inventory of assets are turning to GIS as the tool of choice to manage and display these assets. Over eighty percent of the cost of a GIS is capturing and placing accurate, fully attributed data into the GIS. These costs have prohibited many users from either implementing or fully exploiting the GIS.
A number of different methods have been developed for capturing data in the field. Many users use the data collection method of traveling an inspection route, visually identifying the location, and hand writing a description onto a form or a paper entry. Once the inspector returns to the central data repository the entries so collected are manually entered into a database with questionable accuracy and time consuming labor. The user must build the correlation and association logic into the database to create a useful tool. Back end applications must also be created so that the information is useful to the user. More sophisticated methods include GPS with push button data collection or pen computer data entry units which allow predefined buttons and menus to be used for field data collection. The data can be electronically downloaded into a database, but a user must still build the correlation and association logic. The information downloaded is limited to point information with limited attribute information.
Audio based data entry systems have been developed but are limited to the recording of street point information sequenced with a manually recorded location input. The user is then required to manually convert, transfer, and combine the location data with the audio data. There is no processing of the audio data and manual transcription, and tagging of the entries with location data must be manually performed by the user. Only location data where a observation has been recorded is stored, and all other location information is ignored. Other speech recognition systems require the user to prerecord their speech to replace keyboard entries. None of the described systems provide the automatic population of the GIS with fully attributed and correlated data generated from speech recognition.
As users of spatial data incorporate GIS and GPS based technology, the need for a flexible, true end to end system that collects field data, populates a GIS, tracks field assets, and provides tools to exploit the data will increase.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and system for a speech recognition based field data capture system, asset tracking, and automatic GIS database population tool for a user to build GIS layers, to track assets, and to fully exploit the data in the GIS.
It is an object of the present invention to combine GPS, Speech Recognition, and GIS, and to provide field data collection, automatic GIS database population, and exploitation of the GIS data.
it is an object of the present invention to provide the real time tracking of assets in the field through the combination of GPS and RF communications.
In furtherance of these objects, a field mobile unit capable of continuously capturing feature observations from predefined grammar and free speech, as well as GPS based location information time-stamped and automatically stored on the units onboard memory, is created. Location information is automatically corrected in the field using Differential Global Positioning Service (“DGPS”) and RF wireless data transmission. The location information is automatically combined with observation information to provide a continuous record of locations and observations.
The preferred mobile field unit device is mounted in a vehicle or backpack. The audio headset microphone provides the means for initiating a speech-based description of user observations. The mobile unit computer provides the onboard data storage of speech observations and the GPS time-stamped location signal. The unit provides the ability to electronically transfer field data. The unit provides an audio feedback to the user to optimize speech entry start and stop, as well as notify the user of loss of GPS signal. The grammar structure provides self editing tools as well as a comprehensive description of field observations.
In the preferred form of the invention the location and observation information is transferred electronically to the central data repository or via RF wireless media. The audio data process automatically converts the audio data collected in the field using the semantic information in the reference grammar and creates data records representing the information content of the user's verbal observations. The user can validate and correct observation statements. Interactive tools allow the user to review all speech entries and correct them as required. The results are user validated and grammatically valid.
The preferred form of the invention automatically merges the corrected location data and the recognized text data and precisely synchronizes the verbal data to a location, as well as identifying any continuous span of tracks covered by an observation. The data is then automatically entered into the GIS database and correlated to linear networks and point observations within the central data repository.
The preferred form of the invention provides predefined or customer configurable tools to exploit the data in the central data repository. Work orders, custom reports, and data query scripts are created using these tools.
The vehicle location information is derived from GPS which provides a time-stamp from which absolute location coordinates may be determined through interpolation of recorded GPS data points.
Methods and apparatus which incorporate the features described above and which are effective to function as described above comprise specific objects of the present invention.
Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings, which by way of illustration, show preferred embodiments of the present invention and the principles thereof and what are now considered to be the best modes contemplated for applying these principles.
BRIEF DESCRIPTION OF THE DRAWING VIEWS
FIG. 1 is a diagrammatic view of a spatial asset management system constructed in accordance with one embodiment of the present invention. FIG. 1 shows the processes, the data elements used in the processing, and the user interaction with the system. FIG. 1 is a high level overview of the system.
FIG. 2 is a diagrammatic view showing the details of the 1 . 0 Data Conversion process of FIG. 1 . FIG. 2 shows the 1 . 0 Data Conversion processing in conjunction with the collected data elements and the reference data elements and the user interaction. FIG. 2 shows both the Audio Data 1 .A and GPS Data 1 .B going through their appropriate processing paths and being merged into an Observation 1 .G. FIG. 2 also shows, in the component labeled Track 1 .F, the historical representation of where the field operator had been and when the field operator had been there. The Observation 1 .G and the Track 1 .F are two key outputs of the 1 . 0 Data Conversion process shown in FIG. 2 . Semantic analysis is performed in the 1 . 6 Interpret Text process and by use of the Reference Observation Semantics 1 .E to create the Observation 1 .G.
FIG. 3 is a diagrammatic view showing details of the in the 2 . 0 Data Correlation process of FIG. 1 . FIG. 3 shows the two main data inputs (the Track 1 .F and the Observation 1 .G) coming from the 1 . 0 Data Conversion process shown in FIG. 2 . FIG. 3 shows that Track 1 .F is first correlated to the Reference Network 1 .K. FIG. 3 also shows that the input information Track 1 .F and Observation 1 .G are correlated to the Reference Network 1 .K and to the appropriate other layers of the GIS creating a Tour 1 .L object. The Tour 1 .L object comprises: who collected the data; what data was collected; where the field operator was; what the field operator was doing; when the field operator was collecting the data; and the correlation results.
FIG. 4 is a diagrammatic view showing the 3 . 0 Repository Update process as updated with the Tour 1 .L results. FIG. 4 also shows, the 3 . 3 Define Repository process and the 3 . 5 Configure Tour process, the definition of the repository structure.
FIG. 5 is a pictorial view, in plan, showing an example of data collection in the field. FIG. 5 shows a vehicle traveling north on Elm Street. FIG. 5 shows the position of the vehicle by its GPS points and shows two observation events indicated by the numerals 1 and 2 . The data input from the observation events is voice data, indicated by the quotations in FIG. 5 .
FIG. 6 shows the processing sequence for data conversion for the two specific observation events identified in FIG. 5 . FIG. 6 also shows the semantic analysis of associating observation event 2 to observation event 1 . The results of the semantic analyses are indicated by the inclined block arrow in the lower part of FIG. 6 .
FIG. 7 is a diagrammatic view illustrating the four primary types of data maintained within the Repository 1 .M of the system shown in FIG. 1 . In FIG. 7 the arrows indicate the data structure relationships. As illustrated in FIG. 7, Assets can always be associated with other Assets, Condition must be associated with an Asset, Defect must be associated with an Asset, and Repair can be associated only with a Defect. FIG. 7 also shows the structure for each of the primary data types. The processing information portion of the structure of each primary observation type is embodied in the association (indicated by the arrows), the Spatial Type information, and the Storage Layer and Associated Layers information. Each of the primary observation types also have Location and Attributes in its structure.
FIG. 8 requires too much illustration area to be capable of being shown on one sheet of drawing and is therefore composed of FIG. 8A (on one sheet of drawings) and FIG. 8B (on the succeeding sheet of drawings). FIG. 8 is an example grammar of the type used in FIGS. 5 and 6 but for a specific asphalt distress observation type. Each of the boxes shown in FIG. 8 represent different sentence types. The two observation events illustrated in FIG. 5 correspond to the respective top box and bottom box in FIG. 8 . The semantic information identifying that the second sentence is a modifier of the first sentence is illustrated by the two dashed lines in FIG. 8 —the first dashed line going from “Tag:blob” up to the term “blob” and the second dashed line going from “Tag:area” up to the term “area” in the Observation Template. The observation statements in FIG. 5 correspond to the Recognized Text 2 .A in FIG. 2, and the Reference Observation Semantics 1 .E of FIG. 2 correspond to the information contained in the Asphalt Project Grammar of FIG. 8 .
FIG. 9 is an illustration of the 2 . 0 Data Correlation process using the example illustrated in FIG. 5 and continuing the example shown in FIG. 6 . FIG. 5 shows data collection. FIG. 6 shows data conversion. FIG. 9 shows data correlation. FIG. 9 shows how an observation in track data is correlated to an asset (note the results of the correlation show that the Defect is correlated to the street segment on Elm Street between First Street and Second Street). FIG. 9 also illustrates the process of moving data into the appropriate GIS layers in the spatial asset management system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 presents an overview of a preferred form of the spatial asset management system and method. Subsequent FIGS. 2-4 expand each major process shown in FIG. 1 . For example, the process 1 . 0 Data Conversion (the top circle in FIG. 1) is expanded into a more detailed flow chart in FIG. 2 .
The spatial asset management system and method described herein is a hardware independent system solution for managing assets with a strong geospatial component. The preferred form of the system is implemented in a commercial off-the-shelf laptop or pen-based computer for the mobile system component and a high performance PC for the processing workstation home base computer.
The three data stores Audio Data 1 .A, GPS Data 1 .B, and Sensor Data 1 .C shown in FIG. 1 are generated in the mobile system laptop computer. All subsequent processes and data stores are maintained in the home base computer or workstation.
The system provides for a seamless, fully automatic capture, translation, GIS import, and analysis/processing of asset information as represented by the Audio Data 1 .A, GPS Data 1 .B, and Sensor Data 1 .C stores developed during collection. The mobile unit computer may be hand carried (e.g., backpack) or mounted on a moving vehicle (e.g., car, truck, bicycle).
FIG. 5 illustrates the collection of data whereby the user can drive, or walk along, an inspection route and can comment on observed defects, assets, asset condition or other observations. Also shown in FIG. 5 are the GPS points that are collected by the system.
FIG. 6 shows how the observations in FIG. 5 are processed functionally by the system to become data items that are correlated against existing asset information and analyzed for corrective action by operations personnel.
The mobile unit computer is configured with a commercial GPS receiver (or other location receiver device), a standard commercial sound board, and standard I/O devices (e.g., printer, disc drive, RS- 232 ports) along with a battery or external power source. Other sensor inputs include such sensors as digital cameras, laser ranging devices, and others. For example, digital camera sensor input allows for photos to be included of city code violations. In this case the digital photo image is automatically tagged and tracked by the system so that photo evidence is included directly in the violation report sent to the offender.
Voice observations are automatically correlated with the sensor inputs to be incorporated as an associated data record. The mobile unit computer captures and time-stamps all data store records. Each data store is independent and no other synchronized signal or input is required other than standard precision time. The Audio Data 1 .A store contains all speech audio data detected by the mobile system sound card. The GPS Data 1 .B store includes location derived information containing latitude, longitude, and altitude of the mobile unit on a continuous basis once the unit is initialized. The Sensor Data 1 .C store contains any external sensor records, such as switch on/off states, analog values, digital photos, laser ranging data, etc.
As will be described in more detail with reference to FIG. 2, the 1 . 0 Data Conversion process means receives the mobile unit data from Audio Data 1 .A, GPS Data 1 .B, and Sensor Data 1 .C data stores described above. The 1 . 0 Data Conversion process operates on these inputs in conjunction with reference data (Reference Grammar 1 .D, Reference Observation Semantics 1 .E, and Reference DGPS Data 1 .H) to produce Track 1 .F objects and Observation 1 .G objects data stores. The functions supported by the 1 . 0 Data Conversion process are: (1) automatic interpretation of audio data spoken words using a reference dictionary contained within the Reference Grammar 1 .D data store, (2) automatic detection of word level interpretation error conditions, (3) automatic interpretation of phrases using pre-defined meaning and phrase syntax contained within the Reference Observation Semantics 1 .E data stores, (4) automatic detection of semantic error conditions, (5) optional correction of GPS location data using Reference DGPS Data 1 .H, (6) automatic generation of time-based location Track 1 .F data objects in internal system format, (7) automatic generation of time-based Observation 1 .G data objects in internal system format and (8) operator use of interactive displays to perform Quality Assurance (QA) functions against either Audio Data 1 .A or Sensor Data 1 .C stores.
The net result of the 1 . 0 Data Conversion process is a data store of error corrected track information which is an automated time-sequenced track of the mobile unit's historical travel path with precise latitude, longitude and altitude for a given “Tour” (note that Tours are actually generated by the 2 . 0 Data Correlation process).
Another result of 1 . 0 Data Conversion process is a time-sequenced and operator quality assurance checked set of observation objects, which represent either “discrete” observations (e.g., “tree, foliage damage,” “stop sign, class 1 damage,” “pothole, high, right”), “linear” observations (e.g., “start curb and gutter run,” “end curb and gutter run,” “start road width 32 ,” “end road”), or “polygon” definitions which is a unique form of track data store. These Track 1 .F and Observation 1 .G data stores are available to the 2 . 0 Data Correlation process.
FIG. 6 illustrates the buildup of these data types. The system organizes data into a logical contiguous set of collected data that may last from a few minutes to several hours. A street inspection tour, for example, would typically consist of the collection of street distress data for several hours before concluding the collection and submitting the collected data to the home base workstation for processing.
The “discrete” observations captured include any and all assets which are best categorized as an item or set of items at discrete locations. Examples of types of objects collected are signage, lights, street distresses, concrete distresses, park benches, tree damage, utility cuts, utility access covers, fire plugs, incidences of code violations (e.g., weeds, illegal cars parked, damaged fence, etc.), curb damage, sidewalk distresses, and other items of the like. Usually discrete object observations are accompanied by a status, state, or condition which are related to the object and position, a size, or other descriptive term that may help identify or qualify the observation. The phrase “pothole, medium, right,” would be translated by the 1 . 0 Data Conversion process to mean:
“pothole”=pothole type of road distress;
“medium”=distress severity medium;
“right”=the right lane (assuming more than one lane in the current direction of travel).
Similarly “linear” observations are used for assets or objects that are running or continuous in nature for some significant length. Examples are roads, sidewalks, curbs, gutters, fences, paint stripping, property frontage, and others of the like. Linear objects are usually accompanied by state or condition, plus an indication that the running asset starts or stops at some position.
An example might be when an inspector is monitoring the condition of road centerline paint conditions. A phrase may be “start road centerline paint condition 3 ” which would mean that the inspector is reporting the beginning of a class 3 (e.g., badly worn) status of road stripping condition. This condition may last for several miles. When the condition changes the inspection would terminate the running asset condition with a phrase such as “end road centerline condition 3 .”
The system interprets and keeps track of all running asset states. In addition the inspector may continue commenting on any other objects or observations while the linear conditions are being tracked. That is to say that the inspection can start a running asset observation (like the road paint stripping), then report on several defects (such as sign damage), and then terminate the running asset conditions. The system automatically keeps track of all such interleaved conditions. Logic errors are automatically detected and identified to the operator during the Quality Assurance processing with the 1 . 0 Data Conversion process.
Another observation data type is “polygonal.” Polygonal data is usually associated with defining areas or boundaries. Using a backpack mounted system, a parks inspector might, for example, walk and define the boundaries of an area of a park, perform a tree or endangered species inventory or forest damage by some infestation. The results would be a polygon that describes the area where the observations are located.
As described in more detail below, the 2 . 0 Data Correlation process means operates on the Track 1 .F and Observation 1 .G data stores which are output by the 1 . 0 Data Conversion process means to perform correlation against a variety of reference data. The 2 . 0 Data Correlation process organizes and associates Track 1 .F data stores with Observation 1 .G data stores which are output to produce logical “tours,” which are sets of data (collected by the user) such as those discussed earlier.
The 2 . 0 Data Correlation process automatically routes data items to the proper layer of the GIS database for further processing. For example, signage would be associated with a specific layer of GIS whereas street distresses would be associated with a separate layer. The 2 . 0 Data Correlation process uses the Reference Asset 1 .J data store to correlate the collected discrete asset observation tour data to the existing database of objects (e.g., signs, park benches, etc.) of the same category or class.
The system automatically detects inconsistencies between the collected and reference asset data and brings problems to the attention of the field operator. These inconsistencies can be corrected or edited using Quality Assurance tools provided. Ultimately the reference asset database is updated for future reference.
Similarly, observation tour data which represents discrete defects, (e.g., road potholes, fence damage, curb upheaval, etc.) are correlated and compared against the Reference Defect 1 .I data store and are quality assured for consistency and logical error state by the 2 . 0 Data Correlation process. The 2 . 0 Data Correlation process also performs the same type of functions for linear observations tour data, such as curbing and sidewalk networks, using the Reference Network 1 .K data store. A set of Edit and Quality Assurance tools are provided to support the correlation processing of network type data.
Reference Network 1 .K data stores include simple tour location Track 1 .F data as well (which allows the system to capture and compare location track data independent of collected discrete, or linear objects). This enables the system to identify which inspectors have inspected which streets and when. It also allows a broad range of tour analysis functions to be accomplished, such as, which areas have streets that have not been inspected for the last three months.
The general functionality supported by the 2 . 0 Data Correlation process are (1) automatic association of collected data to proper GIS layers, (2) automatic detection of inconsistencies between collected observations and reference data, (3) correction of conflicted data, (4) analysis of tour location track information such as routes traveled with temporal reference, (5) quality assurance of correlated data, and (6) the organization and association of Track 1 .F and Observation 1 .G into “tours” which are correlated location, observation, and time data sets.
The 3 . 0 Repository Update process means provide all of the tools to create, update, and generally manage the system reference databases. A primary input to this process is the Tour 1 .L data store which is generated by the 2 . 0 Data Correlation process. The 3 . 0 Repository Update process provides the tools to create new assets and/or conditions the system will recognize by updating the Reference Grammar 1 .D data store and the Reference Observation Semantics 1 .E data store along with the appropriate Reference Asset 1 .J, Reference Defect 1 .I, or Reference Network 1 .K data stores. Using this function allows the user to add new types of defects (such as a new type of damage or new class of utility cut in the road), add new asset types, add new tour types (such as utility inspection tours), and any other operational data elements needed.
Data management tools include editing, data consistency checking, data integrity and version control, and backup tools. Operational data store elements are maintained in the Repository 1 .M database. The Repository 1 .M data store is where the results of system processing are placed.
Using a variety of GIS configured, third party, and Spatial Asset System tools, the field operator/user can gain access to the operational database for analysis and reporting purposes. The analysis and reporting tools include both ad-hoc and predefined analysis and reporting capabilities. They range from such capabilities as visual analysis and interrogation of GIS layers to specific reports on such elements as road defect history in a given neighborhood.
The user can query and generate reports on any and all data contained within the Repository 1 .M data stores. Using these tools the user can ask such questions as:
How many of a specific asset type is located within center boundaries?
What are the specific work orders (time to accomplish, etc.) to repair specified road segments?
Show the inspection routes covered by a specified inspector over a given period of time.
Show all road signs that are severely damaged and what is an optimal route for repair.
FIG. 2 is a detailed diagrammatic view of the 1 . 0 Data Conversion process of FIG. 1 . From the field collection process the results of the operator's verbal inputs are represented by the data store labeled Audio Data 1 .A. These are time-stamped digital audio data segments corresponding to each verbal phrase spoken by the field operator.
The data store identified by the label GPS Data 1 .B represents all of the GPS data collected in the field during the operator's trip. The Reference DGPS Data 1 .H store is the DGPS correction data collected during the operator's trip.
The 1 . 1 Correct Location Bias process applies the correction data to the GPS data, if it was not corrected in the field using real-time DGPS. Note that in the preferred implementation the field GPS units can be used in either real-time DGPS mode or post-processing DGPS mode, depending upon the needs of the field operator.
The results of the 1 . 1 Correct Location Bias process is DGPS corrected location data that is then stored in the Corrected Location 2 .B data store. The corrected data is then processed, by 1 . 2 Vectorize Location Data, to convert the individual point data, (typically collected at 1 second intervals, but any interval period is possible), into track data which is stored in Track 1 .F. The purpose of this processing is to compress the point data into a higher order representation of linear and arc based tracks. This compression greatly improves the performance of latter processing illustrated in FIG. 3 .
The 1 . 3 Recognize Audio Data process automatically converts the Audio Data 1 .A collected in the field using the semantic information in Reference Grammar 1 .D, and creates intermediate data records (Recognized Text 2 .A) representing textually/linguistically the information content of the operator's verbal statements made in the field. Note that the field unit can record the audio data in either of two ways. First, it can recognize when voice is present and only record when the operator is speaking, which is the preferred approach. Or the field unit can record all data regardless of whether the operator is speaking.
In the latter case, the 1 . 3 Recognized Audio Data process will break the continuous audio data into the individual spoken phrases using the same approach as the field unit would use, i.e., energy threshold of the audio data. The user then can validate and correct any problems with the results through the 1 . 4 Verify Speech Recognition process. With the interactive tools provided in this process the user can review all of the automatic recognition processing and fix any problems encountered.
The Reference Grammar 1 .D information is used to maintain the integrity of the resulting fixes. The Track 1 .F information is used to provide visual location information to the operator on where they were at the time they made the verbal statement. The results from 1 . 4 Verify Speech Recognition processing are stored into Recognized Text 2 .A. These results are both user validated and grammatically valid.
The 1 . 5 Assign Location process automatically merges the Track 1 .F data and the Recognized Text 2 .A data, precisely synchronizing the verbal data to the location data and identifying any contiguous span of tracks covered by an observation. The resulting merged data is forwarded to the 1 . 6 Interpret Text process. This process uses the Reference Observation Semantic 1 .E information to merge the sequence of recognized text into actual Observation 1 .G.
It should be noted that the system can take a non-contiguous set of verbal statements and combine them into a single observation. An example of this process is discussed latter, relative to FIG. 8 .
The 1 . 6 Interpret Text process performs the semantic analysis on the sequence of recognized text to determine if it is complete and consistent.
FIG. 4 is the diagrammatic view of the repository maintenance functions. The user interacts with the system through these functions to define the data to be collected and merge the collected data into a central data Repository 1 .M. The user interacts with three functions to perform repository maintenance.
The user, through a series of displays in 3 . 3 Define Repository process, defines the data to be collected and the grammars with semantics used to process the collected field data. The user, through a display in the 3 . 5 Configure Tour process, identifies what types of data is collected during his field data collection session. By identifying the types of data collected, the system applies the appropriate grammars and semantics to translate the data collected in the field into database records. The user also enters his name, organization and other relevant information.
The user, through a series of displays in the 3 . 1 Merge Repository Updates process, merges the data collected in the field into the central Repository 1 .M. The assets, conditions, defects, and repairs are compared to the appropriate layer of historical data. Any discrepancies in the data are flagged and presented to the user for resolution. A discrepancy is identified when the new data is not consistent with the data already resident in the central Repository 1 .M. After discrepancies in the data are resolved, the user approves the changes and the central Repository 1 .M is updated.
The 3 . 6 Collect DGPS Data function continuously collects GPS reference data from a connectable Reference GPS Receiver and stores it in central Repository 1 .M. This data is used to correct errors in the field collected GPS data. This correction can be performed post-processed or in real time.
The Repository 1 .M data contains all the data for the system including all data stores discussed in earlier figures. This is data collected in the field, historical data, data used but not changed by the system, and reference data. Central Repository 1 .M contains, as a minimum, the following historical data: Assets, Conditions, Defects, and Repairs. Central Repository 1 .M contains, as a minimum, the following reference data: DGPS Data, Grammars, Semantics, and Imagery.
The Tour 1 .L data store contains the information collected in the field and statistics about the field session. The information contained in the tour is at a minimum: the inspector, data, duration, type of inspection, and correctly formatted repository updates. The 3 . 2 Extract Field Data process provides the function of combining tour data with other historical data stores for processing and use by the user.
FIG. 5 shows an example of data collection in the field. FIG. 5 shows a vehicle V traveling north on Elm street. FIG. 5 shows the position of the vehicle V by its GPS points and shows two observation events indicated by the numerals 1 and 2 . The data input from the observation events is voice data, indicated by the quotations in FIG. 5 .
FIG. 6 shows the processing sequence for data conversion for the two specific observation events 1 and 2 identified in FIG. 5 . FIG. 6 also shows the semantic analysis of associating observation event 2 to observation event 1 . The results of the semantic analyses are indicated by the inclined block arrow in the lower part of FIG. 6 .
FIG. 7 is the diagrammatic view of the four primary observations types. These four observations represent the possible data collected in the field and maintained in the Repository 1 .M and are described in more detail immediately below.
Asset
Asset represents objects in the field that the user wishes to track and maintain. Examples of assets are: street signs, side walks, and curbs. Assets can be related to other assets. For example, a street sign that has one post and two signs attached can be represented as three assets that are associated together. Both Assets and Defects (below) have a spatial type (e.g., point, linear or polygonal). The spatial type and the associated layers information define how the asset information is correlated to other GIS layers during the automatic correlation processing shown in FIG. 3 .
For example, street sign assets may be associated to a side GIS layer. This association defines that the location of the sign asset should be altered during processing to snap (or adjust) its position to be on the street edge, not in the street. Similarly, for defects, such as a concrete defect, (e.g., a crack), will be associated to the concrete network asset layer, which in turn is associated with the street edge layer.
Condition
Condition represents attributes of an asset that change over time and or position. The condition of the assets may be established in the system through grammar tables to allow the user to collect a predefined range and classes of conditions. For example, the conditions for street sign could be good, fair, and poor.
Defect
Defect represents a defined flaw in the asset that affect the health or goodness of the asset. Defects can also be set through grammars to reflect a type of defect or a severity.
Repair
Repair is the removal of a defect. As a repair is made the central data Repository 1 .M can be updated to reflect the repair and the defect is then automatically removed from the database.
The diagrammatic view of FIG. 7 illustrates the four primary types of data maintained within central Repository 1 .M of the system shown in FIG. 1 and also the possible relationships of the types of data. In FIG. 7 (as illustrated by the diagram box in the bottom left hand corner of FIG. 7) the arrows indicate the possible associations of the data structure relationships. Thus, as illustrated in FIG. 7, Assets can always be associated with other Assets, Condition must be associated with an Asset, Defect must be associated with an Asset, and Repair can be associated only with a Defect. FIG. 7 also shows the structure for each of the primary data types. The processing information portion of the structure of each primary observation type is embodied in the association (indicated by the arrows), the Spatial Type information, and the Storage Layer and Associated Layers information. Each of the primary observation types also has Location and Attributes in its structure.
As noted above in the Brief Description of the Drawing Views, FIG. 8 required too much illustration area to be capable of being shown on one sheet of drawings and was therefore composed of FIG. 8A (on one sheet of drawings) and FIG. 8B (on the succeeding sheet of drawings). Since it was necessary to show FIG. 8 on two sheets, the textual content of FIG. 8 is also set out below in this text for convenience in reference.
FIG. 8 is an example grammar of the type used in FIGS. 5 and 6 but for a specific asphalt distress observation type. Each of the boxes shown in FIG. 8 represent different sentence types. The two observation events illustrated in FIG. 5 correspond to the respective top box and bottom box in FIG. 8 . The semantic information identifying that the second sentence is a modifier of the first sentence is illustrated by the two dash lines in FIG. 8 : the first dashed line going from “Tag:blob” up to the term “blob” and the second dashed line going from “Tag:area” up to “area” in the Observation Template. The observation statements in FIG. 5 correspond to the Recognized Text 2 .A in FIG. 2, and the Reference Observation Semantics 1 .E of FIG. 2 correspond to the information contained in the asphalt project grammar of FIG. 8 .
As noted above, FIG. 8 is an example grammar to the type used in FIGS. 5 and 6 but for a specific asphalt distress observation type. This example grammar illustrates one possible implementation of our method. There are two main sections illustrated in FIG. 8 : the Observation Templates and the Sentence Templates. Each of the spoken sentences and the resulting Observation Templates are shown for the examples used in FIGS. 5 and 6.
In the first Observation Template, shrparea, the structure of the resulting observation is defined by the specification enclosed by the “{ }”. The “%s” identifies the type of GIS record to create. The “%t” identifies that time is to be included. The “%p” identifies that location is to be included. The “%e” identifies the several different slot values that are to be included (note the “:center” following the streetpos specification indicates that the value of center is a default). The “%m” identifies that there is a future modifying statement to include, and if not found, then “blob,sqft,50” is the default. The semantic relationship between the two separate verbal sentences is further illustrated by the dashed lines that indicate associations between templates, and between sentences and templates.
FIG. 8 further illustrates the semantic structure of the sentence templates. Each sentence, which corresponds to a set of possible verbal statements, is composed of slots. The information of how slot values are transferred to the observation record is defined by the PrcType attribute of each slot.
For the first sentence “shrpdistressarea” each of the slots are copied into the resulting observation record based on slot tag. For the “areasqft” sentence the numeric values are combined to form a true number that is, by convention, assigned to the “area” slot, with tag “sqft,” and that is then copied into the “sqft%n” specification of the “blob” Observation Template. In this case the “%n” implies a numeric value required. The result of using this semantic information enables the two distinct verbal observations made in the examples of FIGS. 5 and 6 to be combined automatically into one resulting GIS record.
FIG. 9 illustrates graphically the data correlation process for the examples illustrated in FIGS. 5, 6 , and 8 .
While data collection is in progress, GPS data points are continuously collected, as well as the audio data and the other sensor data (see FIG. 2 ). The GPS data record contains the location as well as the time-stamp for that location.
When the system detects voice input by the user, a raw observation is created. This raw observation consists of the recorded voice and a time-stamp. Time is used as the synchronization key between all of the independent data streams: GPS, Audio, and Sensor.
The GPS data points are then compressed into a series of tracks (vectors and arcs) that represent the route taken by the user. Each of the track records consist of a start and stop position. An observation record's location information is determined using time and the GPS data to interpolate the location and the associated track and position along the track. The record consists of the observations text data and other sensor data, the track it was associated to, and the position along the track that the observation was made. These pieces of information are used to correlate the route taken and the observations made to the underlying network segments, which in this example are the street segments that were driven.
In the example shown, the user drives the city streets and makes observations about the condition of the streets. A typical point observation statement is “hole medium.” This observation is correlated to the street network, and a record is added to the Asphalt Distress Layer of the GIS. An example of a running observation is the combination “Segment Start”, “Surface Asphalt” and “Segment End”. These statements make a running observation which would be converted into a series of Asphalt Surface records for each street segment, and partial segment driven over between the “Segment Start” and “Segment End” statements.
Thus, as shown in FIG. 9 the collected GPS data is converted into the Track 1 .F data. The Track 1 .F data is correlated with the Street Network data. FIG. 9 also shows Defect data being loaded into its Asphalt Distress Layer. This Defect data from the Asphalt Distress Layer is then combined with the Street Network correlation results to create the association of the Defect with the Asset. The process from the GPS data layer to the track data layer (illustrated diagrammatically in FIG. 9) is also illustrated by the 1 . 2 Vectorize Location Data process in FIG. 2 . The linkage from the track layer to the street network layer (illustrated in FIG. 9) is also illustrated by the 2 . 1 Correlate Tracks To Network process in FIG. 3 . The input of the Defect data into the Asphalt Distress Layer (illustrated in FIG. 9) is also illustrated by the 1 . 6 Interpret Text process of FIG. 2 . The linkage between the Asphalt Distress Layer and the Street Network Layer (illustrated in FIG. 9) is also illustrated by the 2 . 3 Correlate Observation To Network process in FIG. 3 . FIG. 9 diagrammatically illustrates the example of FIG. 8 with respect to the two events noted on Elm Street as illustrated in FIG. 5 .
While we have illustrated and described the preferred embodiments of our invention, it is to be understood that these are capable of variation and modification, and we therefore do not wish to be limited to the precise details set forth, but desire to avail ourselves of such changes and alterations as fall within the purview of the following claims.
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A data collection and automatic database population system which combines global positioning system (GPS), speech recognition software, radio frequency (RF) communications, and geographic information system (GIS) to allow rapid capture of field data, asset tracking, and automatic transfer of the data to a GIS database. A pre-defined grammar allows observations to be continuously captured along with GPS location and time, and stored on the field mobile unit. A mobile unit's location is tracked in real time or post processed through wireless RF transmission of location information between the mobile unit and a central processing station. The captured data is electronically transferred to a central processing station for quality assurance and automatic population of the GIS database. The system provides for automatic correlation of field data with other GIS database layers. Tools to generate predefined or user defined reports, work orders, and general data queries allow exploitation of the GIS database.
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The Government has rights in this invention pursuant to Contract No. DE-AC03-79ET27131 awarded by the U.S. Department of Energy.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to efficient means for the generation of electrical power by utilizing energy from natural subterranean geothermal sources and, more particularly, relates to arrangements for efficient superheated fluid generation and pumping for application in deep, hot water wells for the beneficial transfer of thermal energy to the earth's surface.
2. Description of the Prior Art
Generally related geothermal power generation systems have been particularly discussed in recent U.S. Pat. Nos. assigned to Sperry Corporation including:
H. B. Matthews--3,824,793 for "Geothermal Energy System and Method", issued July 23, 1974;
H. B. Matthews--3,898,020 for "Geothermal Energy System and Method", issued Aug. 5, 1975;
R. Govindarajan, J. L. Lobach, K. E. Nichols--3,905,196 for "Geothermal Energy Pump Thrust Balance Apparatus", issued Sept. 16, 1975;
J. L. Lobach--3,908,380 for "Geothermal Energy Turbine and Well System", issued Sept. 30, 1975;
H. B. Matthews--3,910,050 for "Geothermal Energy System and Control Apparatus", issued Oct. 7, 1975;
H. B. Matthews--3,938,334 for "Geothermal Energy Control System and Method", issued Feb. 17, 1976;
H. B. Matthews--3,939,659 for "Geothermal Energy System Fluid Filter and Control Apparatus", issued Feb. 24, 1976; and
K. E. Nichols--3,961,866 for "Geothermal Energy System Heat Exchanger and Control Apparatus", issued June 8, 1976.
Systems of the foregoing types may be improved by use of the present invention as will be further discussed in the present specification; in general, they comprise geothermal energy recovery systems making use of thermal energy stored by subterranean heat sources in hot, solute-bearing well water to generate a super-heating working fluid from a surface-injected flow of a clean liquid; the super-heated fluid is then used to operate a turbine-driven pump within the well for pumping the hot brine at high pressure and always in liquid state to the earth's surface, where it transfers its heat in a binary closed loop, heat-exchanger turbine-alternator combination for generation of electrical power. Residual brine is pumped back into the earth, while the clean, cooled working liquid is regenerated at the surface-located system and is returned to the deep well pumping system for again generating heated working fluid. The foregoing patents also illustrate improvement features in the form of hydrodynamic radial and thrust bearings and pressurized liquid bearing lubrication means. A reverse flow, deep well vapor turbine motor of compact nature is also disclosed, along with features of surface control and power generation systems.
SUMMARY OF THE INVENTION
The present invention is an improved geothermal energy extraction system that recovers thermal energy stored in hot solute-bearing well water to generate a super-heated fluid from a surface injected flow of working fluid. The super-heated fluid is then used to operate a turbine-driven pump within the well for pumping the hot well water or brine at high pressure and always in liquid state to the earth's surface, where it transfers its heat content in a binary closed-loop heat-exchanger turbine-alternator combination for generating electrical power. Residual cooled brine is pumped back into the earth, while the clean, cooled working fluid is liquified at the surface-located system and is returned to the deep well pumping system again for generating working fluid. In the related prior art systems, the down-well turbine exhaust returns to the earth's surface separated from the stream of rising hot brine only by the wall of the conduit enclosing the turbine exhaust, thus the rising turbine exhaust picks up a significant amount of heat flow through that conduit to add to the temperature of the already superheated exhaust, all of which super-heat must normally be uselessly dissipated by augmented surface equipment before its condensation and recycling can be effected.
In the present invention, the prior art apparatus is modified to overcome the prior art defect by greatly reducing the flow of heat from the rising brine into the rising exhaust. For this purpose, an insulating conduit is provided for the rising exhaust. Furthermore, thermally conductive fins are added to the conduit for the downward-flowing working liquid; these fins extend from the exterior of the working liquid conduit into the exhaust passageway. In this manner, the heat transfer rate between the turbine motor exhaust and the liquid working fluid is much greater, say ten times, than the brine-to-exhaust fluid heat transfer rate. Accordingly, much of the initial down-well turbine exhaust superheat and the heat extracted from the brine by the turbine exhaust vapor is beneficially inserted into the down-flowing working liquid, which heat is then used beneficially by the down-well turbine as part of its required input driving energy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view, partly in cross-section of the novel deep well geothermal conversion system, also illustrating cooperating surface power-generation apparatus.
FIG. 2 is a cross-section view taken along the line 2--2 of FIG. 1.
FIG. 3 is a graph useful in explaining the operation of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates one embodiment of the novel geothermal energy extraction system as being composed of three major sub-systems. The first or geothermal well sub-system extends from its well head located adjacent the earth's surface 50 for a distance far below that surface into an effective cavity or region where a copious supply of extremely hot water or brine under high pressure is naturally available. An active turbine motor 77 and a brine pump 82 are supported in bearing section 78 adjacent the hot water reservoir within a conventional well casing pipe 51 for operation in the manner generally described in the aforementioned Matthews U.S. Pat. Nos. 3,824,793 and 3,910,050 and elsewhere. In such prior systems, a working fluid is turned into superheated fluid in superheated fluid generator 80 heated by the flow of hot brine past it in well casing 51. The vapor passes from generator 80 to drive turbine motor 77 which thereby drives brine pump 82. The exhausted vapor flows from turbine motor 77 via conduits 63, 55 to the earth's surface, there to be condensed in condenser 23 and returned in liquid form by pump 21 via conduits 22, 53 to vapor generator 80. A second sub-system of the present invention in the form of a brine reinjection well 18 also extends from a location at the earth's surface 50 into deep earth strata which may be horizontally spaced from the aforementioned hot brine source by a considerable distance; well 18 functions to provide a return path for the brine, permitting it to be reheated and recycled by the down-well pump 82 as indicated by arrow 84.
Apparatus at the earth's surface forms a third sub-system and cooperates with the geothermal and reinjection well system according to the present invention, as is illustrated in FIG. 1. It will be understood that an objective of the invention is to generate large quantities of electrical power at terminals 3 at the earth's surface using a conventional fluid turbine 1 driving the electrical power generator 2, both preferably located at ground level. For this purpose, hot brine is pumped to the earth's surface by the geothermal well pump 82, being fed by casing 51 and its extension 19 to element 16 of a conventional boiler-heat exchanger device 15. Apparatus 15 is a conventional closed tank-like device designed to exchange heat between conventional heat exchanger elements 14 and 16 located therein. Elements 14 and 16 may take the forms of lineal or coiled pipes exchanging thermal energy by direct thermal conduction through their metal walls or through a suitable fluid disposed in the well known manner about them. The well pump 82 forces the hot brine upward through the annular region 76 between well casing 51 and conduits 54, 55, 64 and its thermal content is a significant source of heat for supply to the input element 16 of device 15. As in the aforementioned Matthews U.S. Pat. No. 3,910,050, the brine passing through element 16 also passes through pipe 20 after having been dropped in temperature within heat exchanger 15 and is then fed through pump 17, if needed, into reinjection well 18. Thus, the brine and its dissolved mineral salts pumped to the surface in well casing 51 are returned harmlessly into the ground for recycling via path 84 and upward in passageway 76 by pump 82.
The binary surface energy conversion system removes useful energy from heat exchanger 15 via heat exchanger element 14 to operate the conventional surface-located vapor turbine motor 1. For this purpose, a conventional organic fluid affording enhanced Rankin cycle operation may be supplied in liquid form by pump 12 through conduit 13 to heat exchanger element 14, wherein it is transformed into an energetic working fluid that is coupled by conduit 4 to the input stage of turbine 1. After performing useful work therein, the turbine exhaust flows via conduit 5 through input element 10 of a second heat exchanger or condenser 9 and then flows as a condensed liquid through conduit 11 to pump 12 for recycled usage. Condenser 9 may be cooled by a flow of cool water from a cooling tower (not shown) through conduit 6, heat exchanger element 8, and conduit 7. Thus, the combination utilizes energy found in a deep geothermal well for efficient generation of electrical power at terminals 3 of the conventional electrical alternator 2 turned by the organic vapor driven surface turbine motor 1.
Operation of the down-well pump driving loop beneficially uses the exhaust working vapor from the down-well turbine motor 77 that flows upward within the coextensive conduits 64, 55, 54. For example, the exhaust is coupled from conduit 54 through conduit 24 into a conventional condenser 23. Thereupon, the condensed working fluid flows through pump 21 and conduit 22 into the central down-going working fluid conduit 53. As seen in FIGS. 1 and 2, the flow of the liquid is through conduit 53 and out of the radial conduit or manifold 62 into the vapor generator 80, the upper end of generator 80 being closed by an annulus 61.
As further seen in FIGS. 1 and 2, the present invention enjoys improved operation with respect to the prior art by employing a conduit 55 made in the conventional manner of thermally insulating material; it significantly reduces heat flow from the brine in passageway 76 into the rising exhaust fluid within its interior. A metal insulation-covered conduit 55 may alternatively be used. Insulator conduit 55 is threaded or otherwise conventionally joined at 60 to the cylindrical casing 64 which functions as a container for the down-well motor-pump system and also acts as one wall of brine passageway 76. The upper end of insulator conduit 55 is similarly joined at 60' at the surface well-head to conduit 54. In this manner, flow of excess heat from the brine in passageway 76 into the rising exhaust fluid is desirably greatly reduced. The insulation material may be of molded refractory materials cast with a suitable binder and may contain glass or asbestos or similar fibers. Also, turbine motor 77 and brine pump 82 are primarily supported by conduit 55.
Operational efficiency is further enhanced by constructing the central working-liquid injection conduit 53 of a good thermally conducting metal tolerant of its environment and by further supplying it with a plurality of radial thermally conducting fins such as fin 58. Conduits 53, 54, 64 may be made of an alloy steel such as stainless steel. Using these improvements, heat normally added from the brine to the rising turbine exhaust is significantly and beneficially reduced. Furthermore, most of the initial exhaust superheat of the prior art system and any heat extracted from the brine is beneficially inserted into the down-flowing working liquid before reaching the down-well working superheated fluid generator, which heat is thereupon beneficially used in the down-well turbine as part of its required input energy. The working fluids in the binary loop and in the driving loop may be water or preferably may be selected from isobutane, propane, propylene, difloromethane, and other commonly used halogen-substituted high molecular weight refrigerants of the hydrogen-substituted hydrocarbon or chlorofluorocarbon type. The apparatus may be put into operation or stopped using the procedure set forth in the aforementioned Matthews U.S. Pat. No. 3,824,793.
While the structure, operation, and advantages of the invention are readily understood from the foregoing, its features may be further described from the pressure-enthalpy graph of FIG. 3. The line 73 between points 86, 70 represents a gravity head pressurizing process with heating by energy extracted from the rising exhaust of the down-well turbine motor 77 along line 90 between points 89, 91 and by potential energy exchange. The point 70 represents the P-h condition of the working liquid within conduit 53 upon reaching the vapor generator radial entry conduit 62. Along line 71 between points 70 and 72, there is a slight pressurization of the working fluid by gravity, significant heating by direct extraction from the brine to generate the energetic vapor within down-hole heat exchanger 80, and a slight heating by potential energy exchange. The working vapor now has the P-h status of point 72 of FIG. 3 as it leaves generator 80.
The falling curve 75 between points 72 and 91 shows the falling pressure situation brought about by the performance of useful work in driving the down-hole turbine motor 77. The line 90 between points 91 and 89 corresponds to the rising of the down-well turbine motor exhaust toward the surface within conduit 55. A small amount of heat is derived from the brine flowing in casing 51 due to the small, but finite, thermal conductivity of the insulator conduit 55. However, a greater amount of heat is transferred to the down-going working liquid by thermal conduction through the wall of conduit 53. Any heat normally undesirably transferred from the brine through the insulated conduit 55 into the rising exhaust is substantially and beneficially transferred through the high conductivity wall of conduit 53 into the down-flowing organic working fluid. There is an enthalpy-to-potential energy exchange and depressurizing due to the lessened gravity head. Along line 87 between points 89 and 86, de-superheating and condensing occurs, returning the P-h state to that at the top of the working liquid conduit 53. The area 93 bounded by curve 74 defines the dual phase region of the organic or other working fluid of the driving loop. In this manner, a major part of the initial exhaust superheat and the heat extracted by the down-well turbine exhaust is beneficially inserted into the down-going working liquid, which heat is then beneficially and directly used by the down-hole turbine motor. Thus, the need to remove and dissipate such excess heat at the earth's surface is obviated.
While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description rather than of limitation and that changes within the purview of the appended claims may be made without departing from the true scope and spirit of the invention in its broader aspects.
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Geothermal deep well energy extraction apparatus is provided of the general kind in which solute-bearing hot water is pumped to the earth's surface from a subterranean location by utilizing thermal energy extracted from the hot water for operating a turbine motor for driving an electrical power generator at the earth 3 s surface, the solute bearing water being returned into the earth by a reinjection well. Efficiency of operation of the total system is increased by an arrangement of coaxial conduits for greatly reducing the flow of heat from the rising brine into the rising exhaust of the down-well turbine motor.
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BACKGROUND OF THE INVENTION
This invention relates to regenerative furnaces and their operation, and in particular to the type of regenerative furnace commonly employed in the manufacture of flat glass. The regenerators used in such furnaces are usually comprised of a gas-pervious bed of refractory material, such as a stacked arrangement of bricks, sometimes called "checker packing", through which hot exhaust gases are passed during one cycle in order to heat the packing. In alternate cycles, the flow is reversed and the heat stored in the packing serves to preheat combustion air passing through the regenerator. The regenerators are generally employed in pairs, with one on either side of the combustion chamber. While one regenerator is absorbing heat from the exhaust gas, the other is heating incoming air.
Because flat glass furnaces typically include a relatively large number of burner ports (usually about four to eight on each side) spaced several feet apart from one another, the length of a regenerator bed associated therewith usually has a length which is several times greater than its height or width. And because of construction expediencies, the main flue carrying gases to and from each regenerator is usually located at one end of the regenerator. This arrangement unfortunately sets up lateral flow in the upper plenum and therefore an uneven flow distribution in the regenerator packing during the exhaust cycle, which has been found to cause the portion of the packing near the flue to become hotter than other portions of the packing. This localized overheating may often be reinforced in the subsequent firing cycle, during which the flow of incoming air has been detected favoring the end of the packing away from the flue so that the flue end is cooled less than the remainder of the packing. As a result, the flue end portion of the packing tends to deteriorate faster than others, thereby shortening furnace life. Furthermore, because the stored heat is concentrated in one portion of the packing, the efficiency with which air is preheated in the firing cycle is reduced. It is an object of the present invention to overcome these disadvantages.
U.S. Pat. Nos. 1,836,412 and 2,813,708 relate to modifying the flow patterns in regenerators. Both employ rigid baffles designed primarily for the purpose of rendering the air flow through the checker packing more uniform during the firing cycle. It is not apparent, however, how such arrangements could sufficiently influence flow in the opposite direction through the packing during the exhaust cycle to avoid concentrating heat at the flue end of the packing. Moreover, such baffle arrangements could change the gas flow pattern in the space beneath the packing during the exhaust cycle, thereby promoting lateral flow of the exhaust gases along the plenum above the packing and then into the packing at the flue end.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, there is provided one or more movable baffles beneath the packing near the flue entrance to each regenerator, which deflect a substantial portion of the incoming air flow during the firing cycle into the portion of the checker packing nearest the flue, thereby preferentially cooling that portion. When the cycle is reversed, the baffle is retracted so as to not interfere with the normal exhaust gas flow pattern. Since the flue end of the packing will thereby have been cooled more than other portions during the firing cycle, the subsequent uneven flow of exhaust gases will not cause an excessively unbalanced temperature rise at the flue end. Thus inordinate concentration of heat at the flue end is substantially reduced and thermal energy is more efficiently utilized.
Another set of baffles, which may be used either alone or in combination with the first-mentioned baffles, may be located in the plenum above the packing so as to discourage lateral flow along the plenum during the exhaust cycle, thereby alleviating the channeling of exhaust gases through the packing at the flue end. These later baffles need not be movable.
BRIEF DESCRIPTION OF THE INVENTION
FIG.1 is a schematic, vertical section across the width of a cross-fired, regenerative, glass-melting furnace, showing a preferred placement of movable baffles.
FIG. 2 is a vertical section of a regenerator, taken along line A--A in FIG. 1, showing the flow pattern during an exhaust cycle without baffles.
FIG. 3 is a vertical section of a regenerator, taken along line A--A in FIG. 1, showing the flow pattern during a firing cycle without baffles.
FIG. 4 is a vertical section of a regenerator, taken along line A--A in FIG. 1, showing the flow pattern during a firing cycle with a baffle being deployed.
FIG. 5 is an enlarged view of one of the movable regenerator baffles shown in FIG. 1, showing constructional details of the preferred embodiment.
FIG. 6 is a side view of the baffle shown in FIG. 5.
FIG. 7 is a vertical section of a regenerator with a movable lower baffle and rigid upper plenum baffle, showing the flow pattern during an exhaust cycle.
DETAILED DESCRIPTION
The regenerative furnace shown in FIG. 1 is typical of the melting furnaces used in the flat glass industry. It should be understood that such a furnace is being described as an illustrative example, and that the invention is applicable to regenerative furnaces of other types. In FIG. 1, a pool of molten and partially melted glass 10 is contained in a melting zone 11 which also serves as the combustion chamber. Regenerators 12 and 13 flank the combustion chamber and communicate therewith by means of a plurality of burner ports 14 and 16, respectively. Fuel is supplied by pipes 15 or pipes 17. Air for combustion passes upwardly through regenerator 12, where it is preheated by passing over a hot, gas-pervious, brickwork checker packing bed 20 made of refractory materials, and then through ports 14 where it combines with fuel from the pipe 15 at the mouth of each port. Flames issue a considerable distance into combustion chamber 11, and hot exhaust gases pass through ports 16 and into the opposite regenerator 13, where the exhaust gases heat another brickwork checker packing 21. The mode of operation shown in FIG. 1 is a firing cycle with respect to regenerator 12 and an exhaust cycle with respect to regenerator 13. After several minutes of operation, the flows are reversed so that regenerator 13 serves to preheat combustion air, and flames issue from left to right from ports 16 in FIG. 1. Regenerator 12 would then be in an exhaust cycle. After a few more minutes the direction of firing is again reversed, and so on.
Typical flow patterns through the checker packing prior to the present invention may be seen in FIGS. 2 and 3, where lengthwise cross-sections of regenerator 12 are shown. It can be seen there that checker packing 20 rests upon arches 22, leaving an air distributing space 23 below, which is open at one end to a flue 24. A plenum 18 above the packing communicates with a number of burner ports 14. The regenerator is shown serving seven burner ports, a typical number in a large flat glass melting furnace, but the number could be greater or smaller. FIG. 2 depicts an approximation of the flow pattern during an exhaust cycle without the improvements of the present invention. A portion of the exhaust gases tend to be drawn laterally along the plenum, toward the flue end of the regenerator, and then down into the packing near the end. The resulting greater amount of exhaust gas flowing through the flue end of the packing causes that portion of the packing to become hotter than the remainder of the packing. However, in the firing cycle, when flows are reversed (FIG. 3), the air flow through the packing, and therefore the cooling effect, has been found to be somewhat biased toward the opposite end from the flue. As a result, the checker packing near the flue end has been found to continually remain at a higher temperature than the rest of the packing. The region of this inefficient and sometimes harmful concentration of heat is, of course, not discrete, and it depends upon the particular configuration of a regenerator, but it can be said to generally consist of about the first one-third of the packing from the flue end.
The following Table shows an example of the thermocouple temperature readings of a seven port regenerator having approximately the same geometric configuration as that shown in the figures. The temperature readings were taken at the top surface of the packing, within the packing about one third of its height from the top, within the packing about one third of its height from the bottom, and in the airspace below the packing, beneath each of ports one, three, five, and seven (counting from the flue end). It can be seen from the Table that the temperatures at the flue end continually remain higher than any other portion of the regenerator. In fact, in this example, the minimum temperature 1/3 the height below the first port is even higher than the maximum temperatures for most portions of the packing.
TABLE I__________________________________________________________________________Peak Temperatures (Exhaust Cycle) PORTS 1 3 5 7Top 2861° F. 2791° F. 2690° F. 2598° F. (1572° C.) (1533° C.) (1477° C.) (1426° C.)1/3 from Top 2715° F. 2550° F. 2250° F. 2081° F. (1491° C.) (1399° C.) (1232° C.) (1138° C.)1/3 from Bottom 2215° F. 1920° F. 1751° F. (1213° C.) (1049° C.) (955° C.)Bottom Airspace 1860° F. 1700° F. 1575° F. 1470° F. (1016° C.) (926° C.) (857° C.) (799° C.)Minimum Temperatures (Firing Cycle)Top 2710° F. 2600° F. 2482° F. 2378° F. (1488° C.) (1427° C.) (1361° C.) (1303° C.)1/3 from Top 2645° F. 2470° F. 2122° F. (1452° C.) (1354° C.) (1161° C.)1/3 from Bottom 2065° F. 1765° F. 1680° F. (1129° C.) (963° C.) (915° C.)Bottom Airspace 1505° F. 1463° F. 1435° F. 1408° F. (818° C.) (795° C.) (779° C.) (764° C.)__________________________________________________________________________
FIGS. 1 and 4 show the locations of a specific, preferred embodiment of a baffle means in accordance with the present invention. Baffles 30 and 31 are rotatably mounted in the air distributing space 23 of regenerators 12 and 13, respectively. Baffle 30 is shown in an air-deflecting position for a firing cycle, and baffle 31 is shown (FIG. 1) in a retracted, nearly horizontal, exhaust position. When the firing is reversed, the baffles are rotated about a horizontal axis so as to assume the opposite positions. The effect of such a baffle on the air flow during a firing cycle is shown in FIG. 4. Baffle 30, shown mounted, as an example, between the first and second ports, deflects air upward into the flue end of the checker packing, thereby preferentially cooling that portion of the packing. When baffles, such as baffle 30, are employed only in the lower air distributing space, their most effective location would be underlying approximately the first one-third of the checker pacing from the flue end. In the exhaust cycle, baffle 30 is rotated so that its major surface is essentially parallel to the lines of flow around it, or nearly horizontal, so as to minimize resistance to the exhaust gas flow. The flow pattern of the exhaust cycle would then be substantially unchanged from that shown in FIG. 2.
Details of the preferred movable baffle arrangement and the rotating mechanism used therewith may be seen in FIGS. 5 and 6. The body of the preferred baffle 30 is formed from a sheet of metal 32 having cooling pipes 33 welded to its periphery. Cooling water enters at 34 and is drained at 35, preferably following two independent paths around the baffle to assure equal cooling on both sides. Sleeves 36 and bearings 37 rotatably support the baffle within the regenerator chamber. Movement of the baffle is effected by a hydraulic cylinder 40 acting through linkage 41 and lever 42. Lever 42 is affixed to the cooling pipes 33. Cylinder 40 is pivotally mounted on a support 43 which may be attached to the regenerator wall or any other stationary structural member nearby. Preferably, the cylinder is actuated automatically by the same control means used to control the furnace firing cycles.
Preferred baffle 30 is large enough to block about one half of the air distributing space when in the deflecting position, but the size may vary in accordance with the particular requirements of a given regenerator. Moreover, two or more baffles, which may be of different sizes, may be employed in each regenerator to direct the air flow more precisely. It is also permissible to locate the baffles in the upper portion of air distributing space 23, rather than in the bottom half as shown in the drawings. Other variations contemplated by the invention include mounting the baffles so as to rotate about a vertical axis rather than a horizontal axis, or mounting the baffles to swing about one edge thereof, either horizontally or vertically. The movement of the baffles may also be reciprocation through slot openings in the bottom or side walls of the regenerators. The location of the baffle (or baffles) along the length of each regenerator depends upon the temperature profile in the particular regenerator, but in order to deflect air where it is most needed, the baffles should underlie the first one-third of the checker packing from the flue end when baffles in the air distributing space alone are used. Additional baffles may be placed beneath the remainder of the packed bed if further shaping of the flow is desired.
Referring now to FIG. 7, there is shown another variant of the present invention whereby a baffle 50 is placed in plenum 18 above the checker packing so as to impede lateral flow of exhaust gases along the plenum during the exhaust cycle and to direct the gases into the packing. The heating effects are thereby more evenly distributed along the length of the regenerator. Baffle 50 need not be movable, so it may conveniently consist of a rigid wall of refractory material which divides the plenum into two sections. Baffle 50, as shown, completely blocks lateral flow along the plenum, but the baffle may extend only part of the way across the plenum, or on the other hand, it may extend below the top of the packing or even all the way to the bottom of the packing. The plenum may be provided with more than one baffle, but it is generally not desirable to isolate a single burner port 14 from all other burner ports, since blockage of a portion of the checker packing beneath that port could in that case put that port out of service. For example, no more than two plenum baffles should be employed in the seven-port regenerator shown in FIG. 7. When a plenum baffle is provided, a lower baffle 30 is optional, but when used, baffle 30 is preferably located directly opposite the plenum baffle, which in the specific embodiment shown in FIG. 7, is approximately midway along the length of the regenerator packing.
It is to be understood that other modifications and variations as are known to those of skill in the art may be resorted to without departing from the spirit and scope of the invention as defined by the appended claims.
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In a regenerative furnace of the type used for melting glass, localized overheating of the regenerator packing is minimized, heating of the regenerator packing is made more uniform, and regenerator efficiency is improved by employing a movable baffle in the space beneath the regenerator packing and/or by a baffle in the plenum above the packing.
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BACKGROUND OF THE INVENTION
The field of the invention is hand tools for removing and installing a variety of snap rings.
DESCRIPTION OF THE PRIOR ART
Snap rings or clips are formed of hard metal and rigidly resist displacement perpendicular to the flat plane of the cylindrical groove in which they are located in order to perform their function of reliably providing rigid projections from such grooves and thereby locate and/or position adjacent parts and structures relative to such rings and grooves. Adjustment, repair, maintenance, and substitution of such parts and structures adjacent to and positioned by such rings require removal of such snap rings or clips to permit removal of such parts. The removal of such rings is usually attempted by hand tools that usually not only so damage such rings or clips as to render them not useable for re-use, but also such removal by common hand tools is time-consuming, difficult, and not reliable.
The tools of this invention easily, reliably, and rapidly remove and replace such snap rings and clips without damage thereto and permit the reuse of such snap rings or clips.
SUMMARY OF THE INVENTION
While snap rings, and clips, when in place firmly resist displacement along the plane of such ring or clips and so are dimensionally stable in the flat surface of such rings, or clips, they are susceptible to torsion or twisting because they are thin and flat from edge to edge and they have no great strength in torsion along an axis extending the length thereof parallel to the flat surface thereof. On change of shape of a portion of the ring or clip from a flat surface to a twisted surface, at an angle to the plane of the initial flat surface of the ring or clip, the rings or clip are sufficiently flexible in a direction perpendicular to the thus formed plane of the initial flat surface of the ring or clip to be removed from grooves in holding means for such rings or clips.
The group of tools developed to utilize this characteristic of snap rings or clips by this invention provide for applying torsion forces to snap rings and clips to effect a small but definite resilient twisting of a wide or flat surface of such rings or clips, following which shape change such rings and clips are readily displaced in directions parallel to the initial wideflat surface of such rings or clips. Such distortion and displacements by the tools removes the portion or component of the snap ring or clip from the position thereof which holds the snap ring or clip in place and provides for ready removal of such ring or clip from its locked or fixed position. Following such removal of the snap ring, or clip, it may be reliably and conveniently put back in operative position by these tools as the tools also provide for facilitating the return of such rings and clips to their operative position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a chain link assembly to which the tool 40 of this system is applied; this figure is shown partly in a sectional view corresponding to section 1A--1A of FIG. 6.
FIG. 2 is a chain link or clip tool 40 drawn to scale as seen from a side thereof as seen along direction of arrow 2A of FIGS. 5 and 8.
FIG. 3 is a transmission and gear tool 80 according to this invention; it is drawn to scale and shown in side view.
FIG. 4 is a side view of an eye ring tool 60. This figure is drawn to scale and is shown in a side view thereof.
FIG. 5 is an end view of tool 40 as seen along the direction of arrow 5A of FIG. 2.
FIGS. 6, 7, and 8 are, with FIG. 1, a sequence of pictorial, generally perspective, views which show the clip tool in different sequential stages of operation on the clip 114 of the master link of a roller chain belt. FIG. 1 shows the initial engagement of the tool 40 with the clip 114.
FIG. 6 shows the tool being turned about its axis and causing twisting of the flat surface of the clip 114.
FIG. 7 shows the portion of the clip that had initially engaged the groove in the master link pin laterally and vertically (or axially) displaced from that groove.
FIG. 8 shows the clip engaged and displaced and raised over the pin therefor.
FIG. 9 is a perspective view showing the chain clip distortion in an exaggerated manner to illustrate the deformation thereof effected by the tool 40 in steps shown in FIGS. 1 and 6-8.
FIGS. 10-12 are pictorial generally perspective views which show the sequence of stages in operation of the eye ring tool 60 operating on an eye ring 133. FIG. 10 is an initial stage of engagement of the tool and eye ring. FIG. 11 shows a subsequent position of the tool 60 while engaging and twisting the eye ring 133.
FIG. 12 shows the eye ring released from its engagement with the groove in which initially held.
FIGS. 13-16 are top views of the apparatus shown in FIGS. 10-12 diagrammatically showing stages in and direction of movement of the tool 60 and ear 136 of ring 133 during movement of the ear and tool during operation of the tool on the ear.
FIG. 13 is a diagrammatic view taken along the direction of arrow 13A in FIGS. 17 and 21.
FIGS. 14, 15, and 16, respectively, are enlarged views as seen along the direction of arrow 13A of FIGS. 17 and 21 in zone 13B of FIGS. 13 and 11 and show successive stages in movement of the ear of the eye ring of FIGS. 10-12 during stages of movement of the tool 60 at each of the stages also shown in FIGS. 18 and 22, 19 and 23, and 24, respectively.
Each of FIGS. 17-19 is a radial view of the apparatus shown in FIG. 10 diagramatically showing stages in and direction of movement of the tool 60 during movement of the ear 136 and tool 60 during operation of the tool on the ear.
FIG. 17 is a diagrammatic view taken along the direction of arrow 17A in FIGS. 13 and 21.
FIGS. 18, and 19 are enlarged views as along the direction of arrow 17A of FIGS. 13 and 21 and in zone 13B of FIGS. 13 and 11 and show successive stages in movement of the ear of the eye ring during stages of its movement by the tool 60 at each of the stages shown in FIGS. 14, and 15.
FIG. 20 is a diagrammatic perspective view of a tool as 60 enlarged with an eye ring with internally directed ear.
Each of FIGS. 21-25 is a diagrammatic tangential view of the tool 60 and the apparatus shown in FIG. 10 illustrating stages in and direction of movement of the tool 60 during operation of the tool on the ear 136.
FIG. 21 is a diagrammatic view taken along the direction of arrow 21A in FIGS. 13 and 17.
FIGS. 22, 23, 24 and 25 are enlarged views along the direction of arrow 21A in FIGS. 13 and 17 in zone 13B of FIGS. 13 and 11 and show successive stages in movement of ear 136 by the tool 60 at each of the stages shown in FIGS. 18, 19, and 20.
FIG. 25 is a view of a succeeding stage in movement of the ear 136 by tool 60.
FIGS. 26-29 diagrammatically show successive stages in operation of the transmission tool 80 on a transmission snap ring in the zone shown as 26A in FIG. 30.
FIG. 26 illustrates a first stage of insertion or location of a tool 60 behind the ring 173 as seen in a direction of arrow 26A of FIG. 32.
FIG. 27 is a rear view of the structure shown in FIG. 26 and is taken along the direction of the arrow 27A of FIG. 33.
FIG. 28 shows a stage following that shown in FIG. 27 and is shown as in FIG. 27.
FIG. 29 shows the tool 80 during lifting action as seen along the direction of the arrow 29A of FIG. 34.
FIG. 30 is a pictorial and perspective view of the stage of manipulation of the tool 80 in a transmission casing as in FIGS. 26 and 32.
FIG. 31 is an enlarged perspective view of zone 26A in FIG. 30 during the stage of operation of the tool 80 on ring 173 as in FIGS. 27 and 33.
FIGS. 32, 33, and 34 are diagrammatic transverse horizontal sectional views along the section 32A--32A of FIG. 26 and section 33A--33A of FIG. 27 and section 34A--34A of FIG. 29, respectively.
FIG. 35 is a pictorial view of the position of tool 60 and ring 173 operated upon thereby in a stage subsequent to that shown in FIG. 31.
FIG. 36 shows the operation of a tool as 80 in an initial stage of its operation on a gear with a snap ring.
FIG. 37 is a diagrammatic perspective view of a snap ring in a transmission as in FIG. 31 and in a gear ring as in FIG. 36 showing a stage in the deformation thereof and movement thereof by the tool 80.
FIG. 38 shows the tool 80 and the gear ring in a stage of operation subsequent to that shown in FIG. 37.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The tool 40 is particularly adapted to the manipulation of chain link clips. It comprises, an operative combination, a rigid handle 41, a straight shaft 42, and a blade assembly 43 all form of rigid steel and joined firmly to each other. The blade assembly 43 has a terminal tooth 44 which is adjacent to a blade end 45. The blade end is continuous with a rear blade shoulder 46. The rear blade shoulder 46 is spaced away from a front blade shoulder 47 and the front blade shoulder 47 is continuous with a recess 48, the terminal or peripheral end of which recess forms the recess edge of the tooth 44.
While the shaft 42 and handle 41 are circular in cross section as shown in FIG. 5, the blade assembly has a left blade face 49 and a right blade face 50 which are flat and parallel to each other. The recess 48 is generally semicircular in shape. The handle end 51 of that recess is substantially at 90 deg. to the front blade shoulder 46 and the peripheral edges of the recess, 52 are sharp edged forming a sharp angle with the blade faces 49 and 50. The central portion 53 of the recess is at a sufficient depth from the front shoulder 47 to engage as below described a chain clip.
The chain link tool 40 is directed to operate on a roller chain assembly to remove therefrom and add thereto a clip as 114 from the master plate as 111 of the master link.
Generally the chain link on which the tool 40 operates comprises a lower (as shown in FIG. 1) link assembly 101 and a upper link 102 (as shown in FIG. 1) in a series of links joined by the master link plates 111 and 112. The top link 102 comprises a top plate 103, a bottom plate 104, a top roller pin 105, and a bottom roller pin 106 (top and bottom as shown in FIG. 1). The lower (as shown in FIG. 1) link comprises a top plate 107, a bottom plate 108, a top pin 109, and a bottom pin 110 connected in conventional manner. The pins 109 and 106 are joined by a top master plate 111 and a bottom master plate 112. The plates 111, 112, and clip 114 form the master link 113. The clip 114 is formed of hard spring steel with a straight edged left (as shown in FIG. 1) clip plate 115 and a straight edged right (as shown in FIG. 1) clip plate 116, and a circular closed clip end 117 and an openable clip end formed of a left (as shown in FIG. 1) 90 deg. circular end 118 and a right (as shown in FIG. 1) 90 deg. circular end 119 with the ends 118 and 119 meeting at a straight junction 120.
The clip left side plate has an inner edge 121 and the right link side plate has a inner edge 122 which, in their operative position (as shown in FIG. 1), are parallel to each other and engage a groove 126 in the pin 109 and a similar groove 127 in the pin 106. The left end plate 118 has a terminal free edge 123 which is adjacent to the free edge 124 at the end of the right and plate 119. The left side plate inner edge 121 has a portion 125 which engages the groove 127 in the pin 106. The edge 122 has a similar engaging portion which engages the groove 127 adjacent to the portion 125 when the clip is in its operative position as shown in FIG. 1.
In operation of the clip tool 40, the shoulder 46 is located adjacent the clip inner edge of one of the plates such as the right side plate 116. While the tooth 44 is located with the peripheral sharp edge portion thereof between the plate 111 and the bottom edge of the clip left plate 115 as shown in FIGS. 1 and 6, rotation of the shaft 42 for a quarter turn (90 degrees) about its longitudinal axis 43 with shoulder 46 bearing against the right side plate inner edge 122 as shown in FIGS. 6 and 7 with the operator's 159 hand on the handle 41 forces the plate 115 near the portion thereof near the pin 106 to move away from the plate 116 and also causes the inner edge 121 of the left side plate 115 to twist about the outer edge 129 of the plate 115 and cause the left side plate free edge 123 to part from and rise above the right side plate free edge 124. In so doing the engaging portion 125 of the clip 114 that had theretofore engaged with the groove 127 is raised upward from the plate 111. The twisting of the plate 115, as shown pictorially in FIGS. 7 and 8 and shown diagrammatically in FIG. 9, provides that the plate 115 may be readily rotated about the closed end portion 117 to move the edges 123 and 124 away from each other in a plane parallel to the top flat surface of plate 111 as well as vertically in a direction perpendicular to the top flat surface of plate 111. Such movement provides for a resilient distortion of the plate 115 and displacement of the portions 123 and 124 from each other so that the edge 123 is lifted readily and controllably and reliably and resiliently above the top of the pin 106 and the thus vertically displaced edge 123 is set or rested on the top of shaft or pin 106. The tool 40 is then removed from engagement with clip 114. The clip ends 118 and 119 are then readily moved by the operator's thumb or finger or by tool 40 in the direction of the arrow 55 to the dashed line position 56 of clip 114 in FIG. 1 to disengage the openable left end 118 and openable right end 119 from engagement with the pin 106.
On movement of the clip 114 to the position shown in dotted lines as 56 in FIG. 1 the above described operation of tool 40 is repeated and the free edges 123 and 124 similarly moved apart and readily moved over and on and from the pin 109 for removal of the link 114 from the pins 106 and 109 theretofore engaged thereby. This is an extremely rapid convenient and reliable operation because the clip is only resiliently distorted only sufficiently to disengage the edges as 121, 122, 123 and 124 from the grooves in the pins 106 and 109. The distance between the curved circular closed end as 117 of the clip 114 to the closest portion of edges 123 and 124 is sufficient to allow the open clip to pass over pins 106 and 109. The blade assembly 50 where the rear blade shoulder 46 meets the blade faces 49 and 50 is sharp and hard so that during the rotation of the shaft 42 while the edge of the blade shoulder 46, where it joins the blade face 50, contacts the inner edge 122 of the right side plate of the clip 114 the clip is then forced to the right as shown in FIGS. 6, 7, and 8 so that the central ends (i.e. the ends closest to the end 117) of the edges 123 and 124 are moved to the right (as shown in FIGS. 6-8) during the operation of the chain link tool 40 on the clip 114 so as to permit the vertical movement of edge 123 relative to edge 124 and, with such release, the plate 115 is more readily rotated about the end portion 117. The knife edge relationship of the faces 49 and 50 to the peripheral edge 52 of the tooth 44 provides a very small acute angle against the bottom of the surface of plate 115 and the edge 52 of the tooth which does not inhibit the movement of the clip 114 to the right so that the edges 123 and 124 may be moved relative to each other as shown in FIGS. 6-9.
The eye ring tool 60 comprises a rigid handle 61, a straight rigid shaft 62, and a blade assembly 63 firmly joined together. The handle and the shaft are joined at a bent portion 77 and are circular in transverse cross section while the blade assembly 63 is formed with flat faces, 70 and 79. The blade assembly comprises a first terminal tooth 64 and, spaced away therefrom, a second tooth 65. A recess 66 is located between the teeth 64 and 65. A left, (as shown in FIG. 4) and a right blade shoulder are lateral or peripheral to each of the teeth. The inner recess edge 79 is spaced apart from the terminal portion of the teeth 64 and 65. A flat blade surface 70 extends between the edges or shoulder 67 and 68 on one side of the eye ring tool 61 and such surface is generally parallel to an opposite surface 79 parallel thereto.
The eye ring tool 60 operates on an assembly 71 of eye ring as 133 and a machine element attached thereto such as a piston 131. Details of the manipulation of the eye ring by the tool 60 are below set out. Generally the tool 61 is operated to rotate 90 degrees about a longitudinal axis 72 parallel to and extending through the shaft 62. Such rotation provides for a direction 73 of rotation of a tooth which engages an eye of the eye ring and moves such eye ring portion from a lower lateral position as 74 to a central raised position 75 as indicated diagrammatically in FIGS. 13-19 and 21-25. Following such rotation and twisting of the eye ring portion axial movement of the tool 60 is provided which results in complete release of the eye ring from the position in which it had each initially been held and such release is accomplished only by a resilient displacement of the portions of the eye ring relative to each other and such motion is deliberately and readily controlled by the operator.
More particularly a machine element such as a piston 131 is provided with a annular groove as 132 within which a conventional eye ring 133 is located. The eye ring comprises an annular portion 134 with laterally projecting ears 135 and 136 with eyes 137 and 138 in each of the ears 135 and 136. The inner edge 139 of the circular portion or annular portion 134 engages the groove 132 and the outer edge 140 is peripheral or radial thereto. The annular portion has an upper flat surface 141 and a lower flat surface 142. A circular axis 143 extends through the annular portion of the ring. The ring is made of thin, i.e., about 1/16 inch to about 1/32 inch, and flat steel having a width measured radially of between an 1/8 and 1/4 of an inch depending on the size of the ring; generally the width is much greater then the thickness so that the ring is twistable about the annular axis although not readily displaced in the plane of the upper or lower surfaces 141 and 142. Each ear as 136 has an outer edge 144 and a diametrically extending edge 145. The groove 132 is spaced about 1/8 inch, in the apparatus shown in FIG. 10, from the top 146 of the piston. The cylindrical or vertical surface of the piston 147 is at right angles to the flat top surface 146 and a bevel edge 148 is usually provided between the top surface 146 and the vertical surface or edge 147.
In operation of the apparatus 60 the handle 61 is located with one tooth as 65 engaged within the eye as 138 of the ear 136, while the left (as shown in FIG. 4) shoulder 67 of the tool 40 engages the top edge or the edge of the top 146 of the piston. The tool 60 is then rotated 90 degrees or one quarter turn about the axis 72. The axis 72 is held at an oblique angle to the top surface 146 as well as to the radius extending to the piston surface 147 from the longitudinal axis 149 of the piston. As shown in FIG. 13 the axis 72 extends at 45 degrees to the direction of the radius from the axis 149 as seen in the horizontal plane and, as shown in FIGS. 17 and 21, the axis 72 also extends at an angle of about 45 deg. to the line of the vertical axis 149 of the cylindrical piston 131. Accordingly, a 90-degree rotation of the tool 60 with its tooth 64 engaged with the eye 138 of the ear 136 provides a rotation of the ear from the horizontal position as shown in FIGS. 14 and 18 and 22 to the twisted and sloped position shown in FIGS. 15 and 19 and 23. Following such twisting the location of the ear 136 of eye ring 133 is then radially, resiliently, displaced from the position as shown in FIGS. 15 and 23 to the position shown in FIGS. 16 and 24 (and also shown at the top of FIG. 13 in dashed lines). Such radial displacement of the ear occurs on axial movement of the tool 60 along the direction of the arrow 76. Once in such radially displaced position, as shown in FIG. 13 in dashed lines and also in FIG. 11 in perspective, the ear 136 is then readily moved upwardly as shown in FIG. 19 in direction shown by arrow 78. After rotating the tooth 65 located in the eye 138 to displace the ring radially of the groove 132 therefor, as above described and shown in FIGS. 15, 19, and 25, the other tooth 64 is located as shown in full lines in FIG. 13 behind the ring between the inner edge 176 of the ring and the groove in which such rings was theretofore located. Then the tooth 65 is released from the eye 138 and tooth is rotated behind the ring and against the side wall 147 or edge of such side wall and top of piston as shown in dashed lines in FIGS. 13, 16, and 24, and the tool 60 rotated in direction of arrow 156 to pry the ring upward and outward from the position of FIG. 24 and in dashed lines in FIG. 13 to position of FIGS. 12 and 25.
The eye ring is thus readily moved from its initial position attached to piston 131 in FIG. 10 to the intermediate position of FIGS. 15, 19, and 23 to the released position shown in FIG. 12. Generally, the ear of the eye ring is positively moved for a readily controllable distance by initial torsion applied to the ring about its annular axis following which a radial and then upward displacement of the ear is readily effected. Without such torsion, the radial and upward displacement is not a smooth gradual controllable movement but with such tool there is a ready and accurate control thereof.
The transmission tool 80 comprises a rigid straight handle 81 attached substantially at right angles to a rigid straight shaft 82 and a blade assembly plate 83. The blade assembly plate is a rigid flat plate which is firmly attached to the end of the shaft distant from the handle and comprises a tooth 84, next to a blade end 85, which blade end extends from a straight rear blade shoulder or edge 86 to a front blade shoulder or edge 87. The generally straight front blade shoulder or edge has a recess 88. The blade assembly plate also comprises a flat right blade face 89 and a flat left blade face 90. The recess 88 has a outwardly concave handle end 91 and a outwardly concave peripheral portion 92. The central recess face portion 93 is longer than the width of the blade end 85. An axis of rotation 84 extends along the center of the shaft 82.
This tool 80 is directed to the manipulation of a snap ring as 173 in a transmission casing as 160.
In a conventional transmission casing as 160 which casing has a generally axially symmetrical shell wall 161, a plurality of like positions 163-171 are located around and fixed to the interior of the shell wall 161 and form a positioners assembly 162. Each of the positioners has a slot as 172 which serves to position the snap ring 173. The ring 173 is formed of a hard spring metal, as is conventional in such snap rings, and has a upper flat surface 174 and a flat bottom surface 175 with a central or inner edge 176 that is circular and concentric therewith and radial or outer edge 177. Such rings are conventionally split and, as illustrated in FIGS. 30, 31, and 35 have a left free edge 178 and a right free edge 179 which, in the normal operating position of such rings, are adjacent to each other at a junction 180.
The tool 80 is manipulated by an operator 159 to initially locate the blade assembly 83, as shown in FIG. 32, between the radial or outer edge 177 of the ring and the shell wall 161. A subsequent 1/4 turn (or 90 degree rotation) of the tool 80 about the axis 94 is then provided with the tooth 84 located below the bottom flat surface 175 of the ring 173 as shown in FIGS. 26 and 27. Concurrently, pressure downward by the operator is provided so that the handle end 91 of the recess 88 presses downwardly on the upper surface 174 of the portion 179 ring adjacent to the junction 180 of two free ends as 178 and 179 while the rear blade shoulder 86 presses against the wall 161 and the central portion 83 of the recess presses on the outer or radial edge 177 of portion 179 of the ring. This positioning and action causes a twisting as well as a central movement of that portion of the ring as shown in FIGS. 28, 33 and 34. Because of the torsion, as shown in FIG. 28, the ring is readily moved centrally a predetermined distance to allow its escape from slots as 172 in the positioner block as 169. Following such central movement of the portion of the thus twisted ring the peripheral end 92 of the recess at the top of the tooth 83 is able to be moved by the operator to contact and to raise the free edge 179 of the ring 173 as shown in FIG. 35 and thereby move such portion of the ring upward from the level at which it was initially held in the groove or slot within the positioner block 169 and locate the first portion of the ring 173 so initially contacted, manipulated and displaced on the shoulder, as 199, on positioner block 169 adjacent the slot in groove 172 in which such portion of the ring was initially located. Following such contact, manipulation and displacement of such first portion of the ring between positioners 169 and 170 successive portions of the ring initially located in the slot as 172 in positioner block as 170 are similarly contacted, manipulated and displaced and located on an adjacent shoulder as 200 on an adjacent positioner blocks as 170, and then on shoulder 201 of block 171 until the entire ring is removed from the slots or grooves in which initially held and such removal is accomplished conveniently and reliably and rapidly and without buckling of the ring.
The leverage applied by the operator on the handle 81 provides a substantial amount of force through the shaft 82 and plate 83 to the ring and, also, the handle provides for downward pressure by the operator to cause torsion of the ring 173 and so facilitate the manipulation of the ring for a small readily controllable definite amount, within the elastic range, of displacement of that ring so that the ring is removed without damage thereto and may be subsequently reused. For re-use the ring 173 is placed generally in the position as shown in FIG. 35 and then the blade end portion 85 of the tool is used to press the ring downward generally and into place, following which tool 80 is then positioned as shown in FIGS. 34 and 28 to apply torsion to the ring and, using the ring position action shown in FIGS. 34 and 33, the ring 173 is gently moved down so that it snaps into place in a reliable and controlled manner.
The apparatus 60 also serves to manipulate eye rings as 190 in FIG. 20 of which the ears, 191 and 192, extend centrally of the annular portion as 192. For operation on this type of eye ring the tooth as 65 of the tool 60 is manipulated to engages the eye as 194 in ear 191 while the axis 72 of the tool 60 is held obliquely to the central longitudinal axis 195 of the annular portion 193 of ring 190. Such axis is also the central longitudinal axis of the cylindrical apparatus element 196 to which the ring is attached. This oblique angular relationship of axis of tool 60 and axis of the apparatus element holding the snap ring 190 is the same as above discussed in relation to tool 60 and element 131 and illustrated in FIGS. 13, 17, and 21. Tool 60 is then rotated 1/4 turn around its axis 72 (in the direction of the arrow 73 as shown in FIGS. 13, 17 and 21, and then moved axially, or longitudinally of shaft 62 and in direction of arrow 76 as in FIG. 13 and then upwardly as shown by arrow 78 in FIGS. 19 and 20 and in FIG. 24. In so doing the ear 141 is rotated and moved as is the case with ear 136 and as shown in FIGS. 14-16, 18, 19, and 22-25. When so twisted the ring 190 is readily distorted resiliently in a direction extending along the radius of a circle that corresponds to or matches the circular inner edge 198 of the annular portion 193 of the snap ring 190 and the grooves as 197 in which such ring 190 is located on the apparatus element as 196. Following such distortion of the snap ring 190, it is moved out of the groove as 197 in which it had been theretofore located and then controllably and conveniently moved upward and released from apparatus element 196 as above discussed for movement of the ring 133 by tool 60. Similarly, to replace the ring 190 in groove 197 engagement of the tooth 65 of the tool 60 with the eyes 194 in to the ear 191 provides for a ready engagement with and control of position of the eye and of the ear so that the ring 190 may be readily, in its controllably contracted and twisted condition, located adjacent to the groove as 197 in which to be located and then may be controllably and precisely released to be thus readily and conveniently located or installed in such groove as above discussed in regard to the operation of tool 60 in element 131.
FIG. 37 is a diagrammatic and perspective view of the ring 173 such as is in the transmission 160 of FIGS. 26-35 and in the gear ring of FIGS. 36 and 38. FIG. 37 illustrates diagrmmatically the deformation of a snap ring as 173 which is effected by the above-described action of the tools 80 and 60. As diagrammatically shown in FIG. 37, the outer edge 177 of the annular ring 173 is moved inwardly or centrally while the inner ede 176 is also moved centrally and also vertically with respect to the outer edge. This movement of the outer edge permits release of the ring from the groove, as 172 in which held and is facilitated by the twisting of the snap ring material along the circular or annular axis 189 of the ring 173 as the ring may then be readily resiliently bent in a direction perpendicular to the flat face thereof without buckling. The same absence of buckling is provided in the above described slight yet controlled resilient deformation of the clip 114 and eye ring 133. Without buckling there is no permanent deformation of the ring or clip and such ring or clip may be reused. Without the gradual, resilient and limited deformation provided by tools 40, 60 and 80, the risk of producing such buckling is substantial even with highly experienced mechanics. The buckling of the rings and clips causes a permanent deformation or creasing of said rings or clips which not only makes the removal of such rings difficult but also makes impractical any attempt at reuse of such rings or clips in the structure from which it had been removed.
FIGS. 36, 37 and 38 illustrate the application of a modification of the transmission tool 80 to manipulating a snap ring as 173 usually held in a gear ring as used in diesel engines. The tool 80 provides for removal and installation of such type of snap ring in a reliable convenient efficient manner and permits reuse of the snap ring. As shown in FIG. 36, plate 83 of the tool 80 is inserted between the outer edge 177 of the generally flat annular snap ring 173 and the inner surface of the groove for such snap ring in the gear ring. Plate 83 of tool 80 is first located in a space as 186 between interior teeth or lugs 183 and 184 adjacent to the junction as 180 between free edges, as 178 and 179 of the ring 173. Plate 83 is located in a position as shown in FIGS. 26 and 32 between the outer edge of the snap ring and the inner wall 188 of the gear ring. The plate 83 is inserted so that its hook as 84 is located below the lower surface of the ring; the shaft 82 of tool 80 is then rotated up to one-quarter of a turn (90 degrees) with the recess 83 open inward or centrally. Such rotation causes the engagement of the edge of the recess with the outer surface of the ring. Together with a vertical movement of the tool 80 such engagement provides for a twisting of the annular axis 189 of the ring as well as a central movement of the outer edge of the ring, which provides for a twisting of the ring and a central displacement thereof. After a first portion of the ring is twisted and radially contracted, and set or rested on the shoulder of the interior tooth or lug as 184 adjacent the groove in such lug in which that first ring portion was initially located, the tool may be inserted in another neighboring space as 187 between lugs or interior teeth 184 and 185 and be again operated as above described to cause further removal of further increments of length of the ring by similarly resiliently twisting, contracting and displacing successive neighboring or adjacent portions of the ring and moving such portion of the ring out of the groove therefor in the gear structure, and set or rested on the shoulder of the interior tooth or lug as 185 adjacent the groove or slot in such lug in which such successive portion of the ring had theretofore been located, as shown in FIG. 38. The distortion of the ring is illustrated in FIG. 37 where a first portion of the ring is contracted radially, i.e., the radius of the outer edge of the ring is reduced and the radius of the inner edge of the tool is also reduced by the actuation of the tool 80, but not as much as is the outer edge.
The tooth 84 of the tool 80 is thus applied to successive neighboring portions of the ring until the entire ring is, as shown in part in FIG. 38, removed from its position in the gear and such removal is accomplished, without buckling, only by a series of small, resilient deformations of the ring. The tool 80 provides that the limited space available between a shaft as 181 and gear as 182 is still adequate for the reliable removal of each of the successive increments of the ring for from the groove in which initially held.
The rigid and dimensionally stable characteristics of the blade plates 43, 63 and 83 of the tools, 40, 60 and 80, respectively provide that the location and movement of the teeth thereof, as 44, 64, 84, in engagement with the edges of the plates of the clip edges of the rings, and eyes of ears of rings as above described, provides that a limited and predetermined and readily controlled and adequate amount of rotary and radial displacement is effected by the rotation and movement of the shaft as 42, 62 and 82 of the tools 40, 60 and 80. Thereby, only a predetermined and controlled amount of displacement and torsion is effected and the twisting and displacement is thus only effected for a limited, yet predetermined, amount and so avoids any excess movement as might cause buckling of the relatively rigid, yet bendable, shaped plates of which such clips, ears and rings are formed.
In a preferred embodiment of the chain link tool 40, the overall length (blade end 45 to distance end of handle 41 measured along length of shaft 42) is 31/2 inches and handle 41 is 3/4 inch long; blade assembly 43 is 1/16 inch thick and recess 48 is 3/16 inch long and 1/16 inch deep and blade end 45 is 5/16 inch side. The handle 41 and shaft 42 are made of 3/16 inch diameter rod.
The automatic transmission tool 80 is 71/2 inch long total, measured along shaft 82 and handle 81 is 31/2 inch long, both formed of 3/16 inch diameter rod; blade 83 is 1/16 inch thick, 11/4 inch long, and 5/16 inch wide at its end 85. Tooth 84 is 1/32 inch high (measured vertically as in FIG. 3) and recess 83 is 3/16 inch high and 1/16 inch deep. For gears of diesel engines as in FIGS. 36 and 38 (10 and 13 speed) recess 82 is 0.175 inch long and 1/16 inch deep and circular in shape, rather than as shown to scale in FIG. 3 for the transmission tool, the blade end 85 is 3/16 inch wide.
The eye ring clip tool 60 is 81/2 inches long total, measured along shaft 62, and is formed of 3/16 inch diameter steel rod. The handle 61 is 31/2 inch long measured along its length to the center of shaft 62; blade 63 is 11/4 inch long and 1/16 inch thick; the shoulders 67 and 68 are 3/16 inch apart and one tooth (65) is 1/16 inch diameter and the other is 1/32 inch diameter (for different size eyes) and recess 66 is 7/64 inch deep.
The transmission tool 80 is made of welding rod (alloy RG 60, heat 48419). At its tooth 84 the Rockwell hardness is 25-30 on the C scale but the shaft is 11 on Rockwell C scale and the handle hardness is 8 on the Rockwell C scale. The tools 40 and 60 have similar hardness at similar tooth, shaft and handle locations.
The particular size of the clip as 114 varies according to the size of the chain 100. The dimensions of the clip tool 40 accordingly are chosen with respect to such clip size so that the distance from the rear shoulder 46 to the center of the recess 43 are such that there is an angle greater than 45 degrees and less than 80 degrees, preferably 55-60 degrees, between the plane of the surface of the blade face 50 and the plane of the inner edge 122 of the clip at the corner formed by the rear blade shoulder 46 and the rear edge of the face 50 during final (FIG. 8) stage of the operation of the tool 40 on the clip 114 in the relations shown in FIGS. 6, 7, and 8. In the above-described operation of tool 40 on clip 114 the peripheral portion 52 of recess 48, which forms the upper face or top of the razor-sharp tooth 44, engages the bottom of the clip plate 115 adjacent the shaft 106 before the plate 115 begins to be twisted about the longitudinal axis, as 205, or length of such rectangular straight-edged plate (the inner edge 121, and outer edges as 129 of each of the plates as 115 being parallel to each other when such plate, as 115, is flat). The size of the tool 80 is chosen so that as the razor sharp front edge of the tooth 44 first contacts the inner edge 121 of the plate 115 adjacent to pin 106 the angle of the blade surface 49 and such inner edge is about 45 degrees. The curved central portion 53 of the recess 48 cause twisting of the plate 115 on rotation of the shaft 42 as well as displacement of edges 121 and 122 as above described. The minimum distance across the surface 50 from the rear shoulder 46 to the recess 43 is chosen to provide that, as shown in FIGS. 1, 6, 7, and 8 for the preferred embodiment, the plate 115 is twisted about its length as well as displaced away from the inner edge 122 of the other, like plate 116 of the clip 114 on operation of the tool 40. The dimensions of tool 40 given is for a 30-60 type of roller chain; corresponding different size of such tool would be used for different sizes of clips, where the distances between inner edges of plates as 115 and 116 and the dimensions across the blade 43 would be different; FIGS. 1, 5, 6, 7, and 8 are drawn to scale to illustrate the above described relationships.
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These tools efficiently and rapidly remove a snap ring and clips by initially applying a torque thereto along the length of the flat portion of the clip or along the annular length of the ring. When such rings and clips are thus stressed to a limited degree they exhibit resilient twisting or torsion about such axis. The tools are adapted to then displace the portion of the smap ring or clip that provides a locking action on the groove to which the ring or clip was attached in a direction in part at least perpendicular to the wide flat surface of the portion of the snap ring or clip in the vicinity of that then resiliently twisted portion of the ring or clip and so move that portion of the ring that initially provided locking action on the groove therefor in a direction parallel to or along the wider initial plan or surface of the snap of the snap ring or clip surface. Such movement controllably and readily disengages the locking portion of the snap ring or clip. The ring or clip is then controllably moved transversely to the plane of the flat surface thereof to completely remove the ring. The tools also serve to similarly control such snap rings or clips during installation thereof.
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This application is a continuation of now abandoned application Ser. No. 401,980 filed July 26, 1982.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flow rectifier applicable to such equipment as a head box in a paper machine where gas or liquid is fed through widthwise arrayed perforations. More particularly, slits are prepared at the outlet of the perforations, and, from these slits, gas or liquid is fed as a jet (shower) in the form of widthwise extended film.
2. Description of the Prior Art
An example of the head box in the conventional paper machine is shown in FIGS. 1(A) and (B). Referring to these drawings, the flow of the raw paper liquid and the function thereof are described herebelow. Reference numeral 1 designates a rectangular header constituting the flow path, of which the cross-sectional area is decreased while proceeding downstream to uniformly feed the raw paper liquid to a tube bank 2. Furthermore, to make uniform the flow in the widthwise direction, it is so adapted that a part of the raw paper liquid having entered into the rectangular header 1 passes by and re-circulates in the rectangular header 1. Reference numeral 2 designates a tube bank consisting of a group of tapered tubes 3, of which the tube at the inlet side 3a has a small diameter to increase the pressure loss and to obtain uniform distribution in the widthwise direction, while the tube at the outlet side 3b has a large diameter whereby the raw paper liquid enters into a killing port 4 at low speed to facilitate mixing in the flow. In addition, the latter part is given satisfactory length to change the direction of flow by 90°.
Reference numeral 4 designates a killing part characterized by a chamber without a partition throughout the width, aimed at making uniform the pressure and the flow. Reference numeral 5 designates a perforated plate, which functions to cause the pressure loss so that the raw paper liquid is uniformly distributed in the widthwise direction. This perforated plate 5 further functions to uniformly distribute the raw paper liquid in each converging channel 6. Reference numeral 7 is a sluice chamber, and its top plate 9 and a bottom plate 10 converge toward a sluice opening 8. The top plate 9 can rotate with the fulcrum 11 as a center, thereby the clearance at the sluice opening 8 is able to be changed. On the other hand, fine adjustment of the clearance at the sluice opening 8 in the widthwise direction is effected by mechanically flexing a sluice lip 12 by means of the jacking rods (not shown) arrayed in the widthwise direction.
Moreover, as shown in FIG. 3, in the flow following the perforated plate 5, there are a number of irregularities caused in flow speed and by the influence of the jet flow ejected from the perforations. In order to damp down these turbulences in the flow, the inner space of the sluice chamber 7 is partitioned by a plurality of sheet-like restraining elements 13, forming a plurality of converging channels 6. One end 13a of each restraining element 13 is supported on the perforated plate 5, and the restraining elements 13 are held at the same intervals by the flow of the raw paper liquid.
However, the above-mentioned equipment in the prior art had the following shortcomings. That is, it was observed by viewing the flow that there existed a slight local difference in the flow speed in the widthwise direction at the outlet 6b of the converging channel 6. Such local difference in the flow speed causes turbulence in the jet after the sluice lip 12, leading to unevenness of the thickness of the jet. Presumably, such difference in the flow speed is caused by undiminished inherent characteristics of the jet flow imparted by the influence of the perforated plate 5.
In addition, when the highly concentrated raw paper liquid is allowed to flow at low flow speed in the converging channel 6 after the perforated plate 5, as shown in FIG. 2, a plurality of triangular parts 6a with low concentration can be observed in the widthwise direction between the adjacent jets ejected from the perforations in the perforated plate 5. Such triangular parts 6a with low concentration are considered to be caused because the water readily turns into the space between the adjacent jets, while the fiber is liable to flow together with the flow of the jet core, being difficult to turn into the space between the adjacent jets. These streaks with low concentration are observed to be stretched and washed away downstream.
In the meanwhile, in order for the inherent characteristics of the circular jet ejected from the perforation into the water to vanish, the length of the jet flow is generally required to be 12 to 36 times as long as the diameter of the jet flow. When the restraining elements 13 are disposed in the sluice chamber 7, inherent characteristics of the jet flow rapidly vanish; nevertheless, it has been proved that the conventional length of the sluice chamber 7 has not been sufficient to completely make uniform the flow characteristics in the widthwise direction. On the other hand, if the sluice chamber 7 is lengthened, its characteristic frequency is decreased, inner volume of the sluice chamber 7 is changed by the vibration of the top plate 9 and the bottom plate 10, and irregularity is caused in the ejection speed of the jet.
In the head box previously proposed by the inventor, the sluice chamber 7 was lengthened, and characteristic frequency of the sluice chamber 7 was successfully increased up to the practically allowable level, but it is not desirable to further lengthen the sluice chamber 7 to eliminate the influence of ejection speeds. Meanwhile, decreasing the hole diameter of the perforated plate 5 enables the length of the sluice chamber 7 to be shortened, but possible clogging of the raw paper liquid prevents the hole diameter from being decreased to less than the current size.
Originally, uniformity of the raw paper liquid in the widthwise direction is attained by the throttling effect of the tube band 2 and the perforated plate 5. Therefore, if the opening rate of the perforated plate 5 is decreased to heighten the throttling effect, the tube bank 2 may be dispensed with, but, on the other hand, if the opening rate of the perforated plate 5 is decreased to less than the status-quo, the jet speed is increased, and the distance necessary to eliminate the inherent characteristics of the jet is lengthened. Therefore, it was found difficult to make the equipment compact by dispensing with the tube bank 2.
In the meanwhile, FIG. 21 through FIG. 23 illustrate conventional shower equipment where a shower 61 of fluid is ejected from drilled holes 47 in a pipe 46 against a travelling belt 48. FIG. 21 is a perspective side view showing the shower equipment provided in the pipe 46, and FIG. 22 and FIG. 23 are respectively a front view and a cross-section side view of the pipe 46 provided with the drilled holes 47. However, this conventional shower equipment shown in FIG. 21 through FIG. 23 had the shortcoming that the shower 61 was concentrated on the parts directly below the drilled holes 47.
FIG. 24 through FIG. 26 illustrate conventional shower equipment with a slit nozzle. In the equipment shown in FIG. 24 and FIG. 25, a slit 51 is provided in a pipe 49, and the shower 61 is ejected from the slit 51 against the travelling belt 48. In this case, however, machining of the slit 51 is difficult, and, in addition, shortcomings were found. Since the part of the slit 51 was widthwise cut, it constituted the structural weak point and machining could not obtain high accuracy. Furthermore, the opening rate was larger in this case than in the case of the drilled holes 47 and irregularity in flow rate was found in the widthwise direction between the flow-in side and the flow-out side.
In the conventional shower equipment shown in FIG. 26, an inner pipe 52 is provided inside an outer pipe 50, and a slit 53 is cut in the outer pipe 50, while holes 54 are drilled in the inner pipe 52 in the opposite direction. This conventional shower equipment consists of double pipes to reduce the irregularity in the flow rate in the widthwise direction, but also has the shortcoming that the diameter of the outer pipe 50 was inevitably increased unnecessarily.
SUMMARY OF THE INVENTION
The present invention has been proposed for the purpose of eliminating the above-mentioned shortcomings in the prior art, and its principal object is to provide an improved flow rectifier which is collectively provided with the functions of the tube bank, the killing part, and the perforated plate, more specifically, the present invention can obtain uniform flow in the widthwise direction without the influence of the ejection jets from the perforations in the perforated plate by placing the slits directly following the downstream side of a plurality of drilled holes. Thus the present invention can prevent the streak with low concentration from being generated in the raw paper liquid with high concentration and at low flow speed, can reduce the cost, and can improve the vibration resistance of the sluice chamber by shortening the length thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(A) is a cross-section side view of an example of the conventional head box, and FIG. 1(B) is a plan view of FIG. 1(A);
FIG. 2 is an explanatory drawing showing the state of the jet in FIG. 1(A);
FIG. 3 is a detail view of the essential part in FIG. 1(A);
FIG. 4 is an enlarged cross-section plan view of drill plates and slit plates representing an embodiment of the present invention;
FIG. 5 is a cross-section side view of the head box employing drill plates and slit plates representing an embodiment of the present invention;
FIG. 6(A) is an explanatory drawing showing the ejection state of the jet in FIG. 4, and FIG. 6(B) is a front view of FIG. 6(A);
FIG. 7 is an explanatory drawing showing the state of the flow immediately after the drill plates and slit plates;
FIGS. 8(A) and (B), FIGS. 9(A) and (B), and FIG. 10 are respectively a cross-sectional view showing the state of combination between the drill plates and the slit plates representing an embodiment of the present invention other than the embodiment shown in FIG. 5;
FIG. 11, FIG. 12, FIG. 13, FIG. 14, and FIG. 15 are cross-sectional views showing the shape of the slit in an embodiment of the present invention other than the embodiment shown in FIG. 5;
FIG. 16(A) and FIG. 17(A) are cross-section side views showing the hole pattern of the drill plate representing an embodiment of the present invention, and FIG. 16(B) and FIG. 17(B) are respectively the front views of FIG. 16(A) and FIG. 17(A);
FIG. 18 is a perspective side view of the conventional equipment;
FIG. 19 is a front view of the pipe in FIG. 18, and
FIG. 20 is a cross-section side view of FIG. 19;
FIG. 21 is a perspective side view of conventional equipment other than the equipment shown in FIG. 18;
FIG. 22(A) and FIG. 23(A) are front views showing the slit of the pipe in FIG. 21, and FIG. 22(B) and FIG. 23(B) are respectively cross-section side views in FIG. 22(A) and FIG. 23(A);
FIG. 24 is a perspective side view of the shower equipment provided with the drill plates and the slit plates representing an embodiment of the present invention;
FIG. 25(A) is a front view of the pipe in FIG. 24, and FIG. 25(B) is a cross-section side view of FIG. 25(A);
FIG. 26(A) is a cross-section side view of the head box provided with a flow rectifier representing an embodiment of the present invention, and FIG. 26(B) is a cross-section plan view of FIG. 26(A);
FIG. 27(A) and FIG. 28(A) are cross-section side views of the head box representing an embodiment of the present invention other than the head box shown in FIG. 26(A), and FIG. 27(B) and FIG. 28(B) are respectively cross-section plan views of FIG. 27(A) and FIG. 28(A);
FIG. 29 is a plan view for explaining the slit and the slit flow rectifier representing an embodiment of the present invention, and
FIG. 30 and FIG. 31 are respectively a front view and a side view of FIG. 29;
FIG. 32, FIG. 33, FIG. 34, FIG. 35(A) and FIG. 36(A) are cross-section side views of the slit plate and the slit structure of embodiments of the present invention different from each other;
FIG. 35(B) and FIG. 36(B) are respectively cross-section plan views of FIG. 35(A) and FIG. 36(A);
FIG. 37 and FIG. 38 are cross-section side views of a slit plate of different shape from the above-mentioned slit plate of FIGS. 32-36;
FIG. 39 and FIG. 40 are front views showing the combination pattern of the slit plates on an upstream side or a downstream side of the present invention; and
FIG. 41 is a front view of the shower equipment applying a flow rectifier representing an embodiment of the present invention; and
FIG. 42 is a cross-section side view of FIG. 41.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 4 through FIG. 7, description will be made for the first embodiment of the invention. In these drawings, reference numeral 14 designates a rectangular header, and reference numeral 15 designates the first flow control member disposed in the flow path. This first flow control member 15 is a drill plate having a plurality of drilled holes. Reference numeral 16 designates the second flow control member disposed in the downstream side of, and in contact with, the first flow control member 15. This second flow control member 16 is constituted by a slit plate having a slit or slits. Reference numeral 17 is a top plate, reference numeral 18 is a bottom plate, reference numeral 19 is a restraining element, reference numeral 20 is a sluice lip, reference numeral 21 is a sluice flow path, and reference numeral 22 is a sluice chamber.
In FIG. 4 through FIG. 7, the liquid having passed through the drill plate 15 is throttled by the slit plate 16. Since, however, the slit is not restricted in the widthwise direction, the liquid flows while expanding in the widthwise direction. Reference numeral 23 in FIG. 6 designates the low concentration part of the liquid flow.
Explaining now other embodiments of the drill plate 15 and the slit plate 16 than the embodiment shown in FIG. 4 and FIG. 5, FIG. 8(A) illustrates the case where the slit plate 25 is bolted to the drill plate 24, and FIG. 8(B) illustrates the case where the drill plate 24 and the slit plate 25 are integrally constructed. FIG. 9(A) illustrates the case where the drill plate 26 has a widthwise groove 26a, while the slit plate 27 is provided with a widthwise extended projection 27a to be inserted into the groove 26a, and, owing to the engagement of the groove 26a and the projection 27a, the drill plate 26 and the slit plate 27 are fixedly connected with each other. Reference numeral 27b designates a restraining element fitting part.
Then, FIG. 9(b) illustrates the case where the widthwise extended restraining element 28 is held in the widthwise groove 29a of the drill plate 29 by the widthwise extended projection 28a provided on the restraining element 28. A fitting part 28b of the restraining element 28 forms the slit 30.
Proceeding now to FIG. 10, this is the case where the widthwise extended restraining element 31 has the widthwise groove 31a, and into this groove 31a the widthwise extended projection 32a of the drill plate 32 is engaged to hold both. A fitting part 31b of the restraining element 31 forms the slit 33. It is to be noted that, in the above-described embodiments, the drill plate 32 and the restraining element 31 can be made of plastic and other materials instead of metal.
Referring now to FIG. 11 through FIG. 18, description will be made for the configuration of the slit in the slit plate. It is hereby to be noted that the configuration of the end of the slit plate is as shown in FIG. 11 through FIG. 15, but not limited thereto. In FIGS. 11 through 15, reference numeral 34 is the drill plate. In FIG. 11, reference numeral 35 is the slit plate. The slit flow path 35a is tapered in the downstream direction. In FIG. 12, the slit flow path 36a in the slit plate 36 is widening out. In FIG. 13, side walls of the slit flow path 37a in the slit plate 37 are first tapering and then parallel.
In FIG. 14, the slit flow path 39a in the slit plate 39 is inclined against the center line of the drilled hole 34a in the drill plate 34. In this case, the direction of the jet at the outlet of the slit flow path 39a is changed. In FIG. 15, the slit flow path 40a in the slit plate 40 is bent. In this case, therefore, the direction of the jet at the outlet of the slit flow path 40a can be made nearly parallel to the surface of the drill plate 34.
Referring now to FIGS. 16(A) and (B) and FIGS. 17(A) and (B), description will be made for the configuration and pattern of the holes in the drill plate. FIGS. 16(A) and (B) illustrate the drill plate 43 having the holes arrayed in a square pattern, and reference numeral 43a designates the drilled hole in the drill plate 43. In FIGS. 16(A) and (B) and FIGS. 17(A) and (B), reference numeral 44 designates the slit plate. FIGS. 17(A) and (B) illustrate the drill plate 45 having the holes arrayed in an oblique pattern, and reference numeral 45a designates the drilled hole in the drill plate 45.
FIG. 24 and FIG. 25 illustrate an embodiment of the present invention employing the drill plates and the slit plates previously described, wherein reference numeral 55 is the pipe, reference numeral 56 is the drilled hole, reference numeral 57 is the slit, reference numeral 58 is the slit plate, reference numeral 59 is the bolt, reference numeral 60 is the nut, reference numeral 48 is the travelling belt, and reference numeral 61 is the shower. As compared with the embodiment shown in FIG. 18 through FIG. 20, this embodiment can obtain a slit-shaped jet, and display higher performance than the nozzle provided only with the drilled holes 47. Furthermore, as compared with the nozzle provided only with the slit 51 in FIGS. 21 through 23, this nozzle can easily reduce the opening rate and uniformly distribute the flow rate in the widthwise direction. In addition, since the slit 57 includes two plates 58 as shown in FIG. 25(B), the width of the slit 57 can easily be adjusted, and machining is easier than the nozzle provided only with the slit 57 in FIGS. 21 through 23.
Since the present invention is constituted as specifically described above, the jet flow in the form of a widthwise extended film can be obtained after flowing out of the drilled holes 56 and the slit 57, the length of the sluice flow path can be shorter than the prior art, and the uniform flow in a widthwise direction can be obtained. In addition, according to the present invention, since the jet flow extends in the widthwise direction immediately after flowing out of the drill plate and the slit plate 58, the part with low concentration is extremely less than the prior art, and the generation of the streak with low concentration is restricted. Moreover, the sluice chamber is shortened in length and improved in vibration resistance. Also, irregularity of measurement of the paper liquid in the flow direction is eliminated.
Besides the above-mentioned advantages, since the flow rectifier consisting of the drill plate and the slit plate 58 according to the present invention hardly gives rise to irregularity in speed in the downstream side due to the influence of ejection, it enables the opening rate to be reduced, gives the same or more resistance than the conventional prior art (tube bank)+(perforated plate), and can be used in place of the conventional arrangement (tube bank)+(killing part)+(perforated plate), resulting in space saving. Furthermore, since the direction of flow can be changed in the drill plate, the upstream side of the perforated plate can sufficiently be served by the header pipe 55 where the paper liquid flows in the widthwise direction. And, in the slit plate 58, since the paper liquid flows while extending in the direction of the slit, the lump of the fiber is expanded, torn off, and thereby well dispersed.
Now, referring further to FIGS. 26(A) and (B), FIGS. 27(A) and (B) and FIGS. 28(A) and (B), description will be made for another embodiment of the invention. FIGS. 26(A) and (B), FIGS. 27(A) and (B), and FIGS. 28(A) and (B) are cross-sectional views of the head box, wherein reference numeral 14 is a rectangular header, reference numeral 61 is a slit plate in the upstream side, reference numeral 62 is a slit plate in the downstream side, reference numeral 63 is a top plate, reference numeral 64 is a bottom plate, reference numeral 65 is a restraining element, reference numeral 66 is a sluice lip, and the cross-sectional area of the rectangular header 14 is decreased while proceeding downstream by lessening its width.
The upstream slits are formed by the mutual intervals of the slit plates 61, and the downstream slits crossing with the upstream slits are formed by the mutual intervals of the slit plates 62. The sectional area of the flow path in the sluice chamber located in the downstream side of the flow rectifier is increased or decreased by the restraining elements 65.
FIGS. 27(A) and (B) illustrate the head box where the flow rectifier according to the present invention is combined with the sluice chamber so that the sectional area of the flow path in the sluice chamber is increased or decreased by the shape of the wall surface of the sluice chamber. FIGS. 28(A) and (B) illustrate the head box where the flow rectifier according to the present invention is combined with the sluice chamber so that the flow path in the sluice chamber is fitted to the clearance of the downstream slit plate 62.
Proceeding now to the description of the function of the above-mentioned embodiments, in FIGS. 26(A) and (B), FIGS. 27(A) and (B), and FIGS. 28(A) and (B), the raw paper liquid flowing in the rectangular header 14 is diverged into the slits formed by the mutual intervals of the slit plates 61 as flowing in the widthwise direction, thus the distribution in the widthwise direction and the change of direction are realized.
Then, in FIG. 29 through FIG. 31, since the raw paper liquid flowing through the range a passes through the slit b, there exist flows in the directions shown by the arrow marks X and Y. These flows collide with each other at the slit formed by the slit plate 76. Since, however, the flow is restricted in the direction shown by the arrow mark Z, it is rapidly expanded in the direction shown by the arrow mark Y. In these drawings of FIG. 29 through FIG. 31, reference numeral 75 is one slit plate, and reference numeral 76 is another slit plate fitted by the bolt 77 in the downstream side so that both slit plates 75 and 76 are crossing with each other.
Then, the means to form the mutually crossing slits will be described herebelow with reference to FIG. 32 through FIGS. 36(A) and (B). In FIG. 32, the slit plate 78 has the projection 78a perpendicular to the sheet surface, which is fixedly inserted into the groove 79a perpendicular to the sheet surface of the slit plate 79.
In FIG. 33, the restraining element 80 extending perpendicularly to the sheet surface has the projection 80a, which is fixedly inserted into the groove 81a of the slit plate 81. The slit is formed by the fitting part 80b of the restraining element 80. The arrow mark A shows the direction of flow.
In FIG. 34, a groove is provided in the restraining element 82, and a projection is provided on the slit plate 83. The slit is formed by the fitting part 82a of the restraining element 82. Again, the arrow mark A shows the direction of flow.
As shown in FIGS. 35(A) and (B), mutually crossing slits 85, and 85a can be formed by the integrally constructed slit plates 84 and 84a. In this case, it is possible to give sufficient depth to the slits 85 and 85a to cross them directly, but it is also possible, as shown in FIGS. 36(A) and (B), to give smaller depth to the slits 87 and 87a of the slit plates 86 and 86a and connect them through the medium of the hole 87b. Furthermore, the downstream slit 87a in FIG. 36 can be formed by the restraining elements 80 and 82 as shown in FIG. 33 and FIG. 34. It is to be noted that, in the above-mentioned embodiments, the slit plates 81, 83, 84 and 86 and the restraining elements 80 and 82 can be made of plastic and other materials instead of metal.
As shown in FIG. 37 and FIG. 38, the direction of the jet flowing out of the slit can be changed by changing the slit angle, i.e., the shape of the downstream slit plate 88 and 89. In these drawings for FIGS. 37 and 38 reference numeral 61 designates the upstream slit plate. It is to be noted that the slit plates 61 and 88 or 89 can be crossed in the same manner either orthogonally as shown in FIG. 39 by slit plates 90 and 91 or obliquely as shown in FIG. 40 by slit plates 92 and 93. It is further to be noted that, although in the above-mentioned embodiments the flow path of the raw paper liquid passes through the first slit and then crosses the second slit, the number of steps of this crossing may be increased to three or more steps.
FIG. 41 and FIG. 42 illustrate the shower equipment applying the slit and the slit flow rectifier representing the embodiment of the present invention. As shown in these drawings, the slits 95, shaped into slender configuration in the circumferential direction of the pipe 94, are formed along the lengthwise direction of the pipe 94. The slit plates 96 and 97 form the slit 98 in the lengthwise direction of the pipe 94. The slit plates 96 and 97 are fixed to the pipe 94 by the bolts 99 and 100.
The raw paper liquid having flowed in the pipe 94 along its lengthwise direction causes at the slit 95 the flow as shown by the arrow mark Z in the circumferential direction of the pipe 94. This flow is turbulent at the slit 98. Since, however, the flow is restricted against the end surfaces 96a and 97a of the slit plates 96 and 97, the flow expands in the lengthwise direction of the pipe 94, causing the flows shown by the arrow marks W and V. Thus, a jet in the form of a widthwise continuous film is obtained from the slit 98. In this case, since the slit 98 continuously extended in the lengthwise direction of the pipe 94 is not required to be cut, the pipe 94 is rarely deformed by the liquid pressure. In addition, the flow rate can be adjusted by changing the clearance of the slit 98 by simply adjusting positions of the slit plates 96 and 97.
As clearly known from the specific description stated above, this embodiment provides the same function and effect as the previously described embodiments.
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A headbox for a paper-making machine having a flow rectifier which comprises a first flow control member disposed in a flow path and a second flow control member disposed in a downstream side of the first flow control member. Being in contact with the first flow control member, the second flow control member is so constituted that the flow stagnation phenomena generated by the first flow control member is eliminated by the second flow control member. In other words, a uniform flow rate distribution or speed is achieved across the outlet of the second flow control member by rapidly decelerating the flow therein.
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BACKGROUND OF THE INVENTION
The present invention relates in general to building structures, and, more particularly, to building structural support elements and coverings used in space frames, such as geodesic domes, or the like.
Many buildings have sheeting type coverings for the roofs thereof. Such sheeting must prevent moisture from entering the building, but also should be as easy as possible to install.
Prior art roof coverings are often difficult to install and often require special tools and specially skilled personnel to effect the roof covering installation. Gaskets and other such sealing elements are usually required. Such special requirements increase the cost of building construction, increase the time required to erect the building, and may even reduce the integrity of such buildings. The drawbacks are especially important in buildings having geodesic dome type roofs.
Accordingly, there is need for a building roof which can have any roof covering used therefor easily and quickly installed without requiring special tools and/or skills and which does not require gaskets to effect a secure seal.
SUMMARY OF THE INVENTION
The roof structure embodying the teachings of the present invention has means for permitting easy and secure roof covering installation, and does not require special tools or special skills to effect a secure installation. The sheeting can be installed without need of any gaskets between that sheeting and the roof structural elements supporting that sheeting.
The device of the present invention is especially applicable to space frames, and such application is the preferred embodiment. However, those skilled in the art will recognize other applications based on the description presented herein. Thus, while space frames will be disclosed herein, no limitation is intended thereby. It is also noted that terms such as "top" and "bottom" are terms of convenience, and no limitation is intended thereby.
A strut has a longitudinal channel defined therein with a fastening slot extending the length of that strut. A clamping bar having a corrugated bottom and a plurality of fastener receiving holes defined therein is received in the channel. The channel has ridges which are located adjacent lands located between the corrugations of the clamping bar.
Sheeting is crimped between the clamping bar and the channel bottom to attach that sheeting to the strut. A gasketless seal is formed.
Fasteners, such as screws, or the like, are used to attach the clamping bar to the strut, and thus no special tools or skills are required to quickly, easily and securely attach the sheeting to the strut.
OBJECTS OF THE INVENTION
It is a main object of the present invention to quickly, easily and securely attach sheeting to a roof strut.
It is another object of the present invention to quickly, easily and securely attach sheeting to a roof strut without need of gaskets.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming part hereof, wherein like reference numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective showing a roof strut embodying the teachings of the present invention.
FIG. 2 is a top plan view showing a roof strut embodying the teachings of the present invention attached to a joint connector.
FIG. 3 is a view taken along line 3--3 of FIG. 2.
FIG. 4 is a view taken along line 4--4 of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Shown in FIG. 1 is a strut 10 which, in the preferred embodiment of the present invention, is used in a space frame with a joint connector J as shown in FIG. 3. The joint connector J is the subject of a co-pending patent application Ser. No. 138,526, filed on Apr. 8, 1980 by the present inventor.
The strut 10 includes a web 14, a pair of co-planar lower flanges 16 and 18 and a pair of co-planar upper flanges 20 and 22 integrally connected to the web to form an I-beam configuration. A plurality of grooves GT and GB are defined transversely of the strut to accommodate flanges FT and FB, respectively, of the joint connector to attach the strut to that joint connector, as shown in FIGS. 2 and 3.
A boss 30 is defined on the strut between the lower flanges 16 and 18 and a crown section 32 is defined on the beam upper section between the flanges 20 and 22 and the web 14, as best shown in FIG. 4.
A channel 40 is defined in the strut to extend longitudinally of that strut. The channel is rectangular in transverse cross-section and extends the length of the strut. The channel is open-topped, and has inner side walls 42 and 44 which are in spaced parallelism with each other, and a bottom wall 46 extending in spaced parallelism with the top flanges 20 and 22.
A fastener slot 48 is defined in the beam crown section to extend the length of the strut. The slot 48 is open-topped and is rectangular in transverse cross-section. The slot has side walls 50 and 52 and bottom 54 which is in spaced parallelism with the channel bottom 46.
A pair of ridges 60 and 62 are defined on the channel bottom 46 to be on either side of the fastener slot and to project upwardly from the channel bottom into the channel. Preferably, the ridges are triangular in cross-section with the apeces thereof located within the channel. The ridges extend the entire length of the strut.
A clamping bar 70 is located within the channel 40. The bar 70 has a length essentially equal to that of the strut and a width slightly smaller than the width of the channel 40. The bar 70 has a plurality of spaced fastener receiving holes 72 defined longitudinally thereof. The holes 72 are positioned to be aligned with the slot 48 when the clamping bar is in a clamping position as shown in FIG. 4. The clamping bar is rectangular in transverse cross-section and has a top 74 and a pair of side walls 76 and 78. The bar 70 has a corrugated bottom wall 80 which has four ridges 82, 84, 86 and 88 extending lengthwise of the bar, and lands 90, 92 and 94 located between the ridges. The ridges are positioned to straddle the channel ridges 60 and 62 so that the channel ridges correspond to the clamping bar lands, as best shown in FIG. 4.
A plurality of fasteners, such as screws 96, or the like, couple the clamping bar to the strut via the slot 48. The slot 48 has a width selected so that the fasteners securely attach to the slot side walls 50 and 52. The slot permits easy positioning of the clamping bar as the fastener holes 72 need only be aligned with the slot transversely of the channel, and no longitudinal alignment is required.
Deck covering 100 includes a pair of deck sheets 102 and 104 which are attached to the strut 14 by the clamping bar. The deck sheets are each positioned to have one edge thereof adjacent the fastener slot 48, and the clamping bar is tightened down thereby crimping the deck sheets and attaching those sheets to the strut. The attachment of the deck sheets to the strut is secure, yet is accomplished without need of a gasket. A gasketless seal is thus formed.
As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is, therefore, illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the metes and bounds of the claims or that form their functional as well as conjointly cooperative equivalents are, therefore, intended to be embraced by those claims.
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A roof strut permits easy attachment of roof covering material thereto. The strut has a channel defined therein and a clamping bar is positioned within the channel to sandwich roof covering material between that bar and the strut to form a gasketless seal.
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OBJECT OF THE INVENTION
The present invention, tooth and adaptor for dredging machines, relates to a tooth or wear member which, attached to an adaptor or adaptor member, creates an assembly the purpose of which is to deepen and clean the beds of ports, rivers, channels, etc., removing therefrom sludge, stones, sand, etc., the adaptors being attached to the blades of the propellers and thus forming the cutter head of the dredging machine.
The dredging machine, or dredger, allows excavating, transporting and depositing material that is located under the water, and they can be mechanical or hydraulic machines, the mechanical machines being used with cutting members, teeth or blades for their use on compact terrain.
The tooth and adaptor object of the present invention are preferably intended to be used in dredging machines having a suctioning cutter head of the type which while at the same time it excavates the terrain under the water, the loosened material is suctioned by a pump and transported through a pipe to somewhere else.
STATE OF THE ART
Systems of tooth and adaptor or adaptors are known in the state of the art for their application in dredging operations. The main objective of said operations is to remove material from marine or river beds, and to do this it is common to use dredge boats including a dredge or dredging machine on which the various teeth are arranged and in turn connected to tooth bars or adaptors.
The U.S. Pat. No. 3,349,548-B describes a tooth and adaptor system attached to one another by means of an elastic strap such that if such strap is poorly arranged, the entire system is altered as to its correct assembly. It also only has one contact area between the tooth and the adaptor, which negatively affects the distribution of stresses.
Another, also US, U.S. Pat. No. 4,642,920-B describes a tooth and adaptor system attached to one another by means of a retaining system formed by a pin, the area where the pin is housed being easily accessed by dirt, making the subsequent removal thereof difficult. This system presents difficulty in absorbing the torsional and bending stresses and loads, generating a strong lever reaction in the system. As with the preceding patent document, there are few contact surfaces between the tooth and the adaptor.
Spanish patent document number ES-2077412-A describes a tooth and adaptor assembly made up of three parts requiring the use of two fastening systems. The fact that it has three parts complicates the entire system because it requires a larger number of spare parts and three fastening systems, one of which requires the use of a hammer whereas the other two fastening systems are formed by welding, making the tasks for replacing them long and complex.
The solutions existing in the state of the art for dredging machines have, among others, the following drawbacks:
The teeth are solid members such that the material of said members is not optimized for the functions for which it has been designed. Another drawback of using the solid teeth known in the state of the art is that they are more difficult to handle due to their weight. The teeth used in the state of the art for the same application are larger, requiring more space for storage thereof. The interlockings between tooth and adaptor known in the state of the art have a retaining member or vertical pin assuring the attachment between said tooth and the adaptor during operation thereof. When the tooth becomes worn it is necessary to replace it and to that end the cutter head is taken out of the water and usually has material from the aquatic bed where it is working adhered to the lower part of the teeth and adaptors. Said pin is usually removed by striking said pin at the upper part and re moving it through the lower part of the tooth-adaptor assembly, which often causes the pin to fall into the water (since the tooth is changed above the water) preventing recovery thereof. Likewise, the fact that there is material adhered to the lower part of the tooth-adaptor assembly makes it difficult to remove the mentioned pin because it prevents the pin from coming out of its housing. Furthermore it is common for the pin to be lost when it is inserted in the mass of material adhered to the assembly and subsequently falling into the water. Due to the configuration of the interlockings existing in the state of the art, the teeth are excessively large, generating long interlockings, with less strength in the tooth, a larger occupied volume and an increase of the distance from the cutter head to the blade, which reduces the performance of the tooth and the assembly. The adaptor likewise has no additional protection other than the protection provided by the tooth and is affected by the materials loosened due to the action of the tooth and striking against the adaptor, causing damage and wear thereof.
DESCRIPTION OF THE INVENTION
The invention describes a tooth with a front wear part and a rear projecting part or nose intended for being housed within a hollowing arranged in the body of an adaptor and an assembly formed by both for dredging machines, both members being attached to one another by means of a preferably hammerless, preferably vertical-type, retaining system, i.e. without needing to use hammers or without having to strike the pin attaching both members to one another. The adaptor is attached to the blade of the cutter head of the dredging machine at the end opposite to the hollowing by means of a coupling adapted for such purpose.
The object of the present invention is a tooth, an adaptor and the assembly formed by both, preferably applied to dredging machinery, allowing optimal wear of the material of the tip of the tooth and coupling between the tooth and the adaptor. These objects of the invention are achieved due to a particular construction of the contact surfaces between both members, allowing the self-tightening force to be produced close to the force (load), such that the horizontal component of the rearward reaction is larger and therefore the self-tightening force is also larger since the tooth pushes against the adaptor.
In dredging operations the tooth must be replaced on the actual dredge boat, i.e. at the worksite or the operations area, usually on the water and working directly on the cutter head carrying the adaptors, or tooth bar, and the teeth. Said operations are carried out by the employees on said boat, i.e. at the work site, far from maintenance shops with the suitable conveniences and tools for optimally performing these types of operations. For this reason all the mentioned components can be coupled with fastening members and pins so that the replacement operations are simple, without an excessive number of tools and preventing the use of complex equipment.
Another object of the present invention is to present in addition to the tooth-adaptor assembly, a tooth as well as an adaptor which, due to their configuration, allow a distribution of stresses that favors retaining the tooth in the adaptor and reducing the stresses to which the retaining system, and specifically the pin thereof, is subjected. The configuration of the tooth and of the adaptor can also be used outside of dredging operations, such that the adaptor or tooth bar can be connected to the bucket of an excavating machine or the like for on-shore works.
The tooth and adaptor object of the present invention have contact surfaces and constructive features allowing the coupling between both members to increase the performance of the coupling, particularly the efficiency of each tooth, thus improving the efficiency of the dredging machine.
The tooth is made up of two different parts, a first wear part, which is the part acting on the terrain and is subject to erosion due to the terrain, and a second part or nose, which is the part that is inserted in a housing arranged for such purpose in the adaptor, forming the interlocking of the system, and subjected to the reactions and stresses generated by the work of the tooth on the terrain. Said nose is formed by a lower base body and an appendage integrated in the upper surface of said lower base body, one of its ends being free and at the opposite end said nose is attached to the wear part. The gap between the wear part and the nose is determined by the upper surfaces of the appendage and by the lower surface of the lower base body which, after reaching a maximum height from the free end of the nose, converge towards the tip of the tooth, such that the union line of both surfaces is located on the side of the wear part of the tooth and in front of the line of maximum height of the nose.
The longitudinal vertical section of the nose varies along the length thereof, and has at the free end thereof a cross-section with rounded vertices. The area of the cross-section of the nose gradually increases as the nose approaches the end for being attached to the wear part of the tooth, specifically until a maximum height is reached between the lower side of the base body and the upper side of the appendage of the base body. After this point the area of the cross-section of the nose begins to decrease until the upper surface of the appendage intersects with the lower surface of the base body.
Said section can have different shapes, such as elliptical, trapezoidal or rectangular shapes, but having at least four sides.
The appendage located in the upper part of the nose, and the trapezoidal cross-section of which is narrower than the section of the base of the nose, is centered with respect to the latter. The height of said appendage is preferably nil in an area close to the free end of the nose (although it is possible for the appendage to have a certain height at said free end) and such height gradually increases until reaching said point of maximum height before decreasing again. The lateral sides of the successive cross-sections of the appendage and the upper side of the successive cross-sections of the base body of the nose of the tooth form an angle varying, due to manufacturing issues, between 45° and an angle of less than 180°, preferably between 45° and 135°. Even more preferably the angle is greater than 90°, such that the lower base of the appendage is larger than the upper base, although the opposite is also possible, i.e. the angle is less than 90°
The nose likewise has at least one first contact area with the inner surface of the housing of the adaptor, such contact area being formed by the two upper surfaces of the base of the nose that are located on both sides of the appendage of the nose of the tooth. The main feature of this first contact area is that it achieves the self-tightening of the tooth in the adaptor.
Due to the proximity of these surfaces with the tip of the tooth, i.e. the point of application of the force produced during the work of the tooth on the terrain, causes the reactions on said surfaces to be greater and therefore the self-tightening forces (components of said reactions} are also greater.
The nose has a second contact area with the adaptor, this contact area being located on the lower surface of the base of the nose, in the area close to the free end thereof.
The adaptor is also made up of two parts: at one end it has a configuration that can vary depending on the type of machinery to which it is connected, i.e. either a cutter head of a dredging machine, or to the bucket of an excavating machine, whereas at the opposite end it has a hollowing, housing or cavity intended to receive the nose of the tooth. The inner configuration of the surfaces of the hollowing or housing of the adaptor for receiving the tooth are complementary to that of the nose of the tooth, thus assuring a perfect coupling between both members.
For the coupling between the tooth and the adaptor, both parts preferably have a hole or through borehole from the upper part of the adaptor, traversing the nose of the tooth, and to the lower part of the adaptor. A pin preferably with surfaces of revolution and with a preferably hammerless retaining system (which does not require striking with a hammer or mallet for being inserted or removed) aiding in changing teeth in the adaptor will be inserted in said housing.
The coupling of the rear part or nose of the tooth in the hollowing or housing of the adaptor is due to the conjunction of the planes defining the described locking surfaces. A tightening or crushing effect between the tooth and the adaptor is furthermore achieved by means of said planes when a stress is applied perpendicular to the wear tip of the tooth and upwardly, this being the normal working situation of the teeth in a cutter head of a dredging machine.
Due to this interlocking system, the pin is subjected to fewer stresses than in conventional interlocking systems since the to oth-adaptor system tightens itself when it is subjected to upward vertical loads in the tip of the tooth, releasing stresses into the retaining system and its pin, and therefore allowing designing pins of the retaining system with a smaller size and section since they are subjected to fewer stresses, thus reducing deterioration or mattage of the pin and allowing it to be reused.
With the described configuration of the coupling the contact surfaces between the tooth and the adaptor are closer to the working tip of the tooth than in known couplings. This reduces the lever effect created between the tooth and the adaptor, and therefore the stresses to which the assembly is subjected, including the fastening or retaining system, are also reduced, thus reducing deterioration or mattage. Reducing lever stresses in the tooth allows reducing the dimensions of the nose of said tooth. And furthermore, due to its geometry, the resistant section of the rear projection or nose decreases towards the free end thereof, such that the bending moments in said area, caused by the load at the tip of the tooth, decrease and therefore the larger moments are located at the point where the resistant section is larger. Reducing the total dimensions of the system also allows therefore reducing the height of the interlocking, thus achieving a more deeply penetrating system.
The tooth object of the invention together with the adaptor allows optimizing the wear material, i.e. the use of the material arranged in the front wear part of the tooth, which is the part that directly acts on the terrain, is optimized. Said optimization is achieved by reducing the material of the tip of the tooth that is not going to be used to a minimum. The material forming part of the tip of the tooth, or wear tip, and which is then not worn, is material that has been paid for but then not used for its purpose. The material of the tip of the tooth is optimized because the tip has been designed according to the inclination of the upper surface of the appendage of the nose, which is parallel to the line of wear of the tooth, thus making use of the largest possible amount of material at the tip of the tooth before being replaced with a new tooth.
Due to this configuration of the tooth-adaptor coupling, and taking into account that dredging operations are done “blindly” for the user, the tip of the tooth must be completely worn, the unused wear material being minimal, before the tooth bar begins to become worn, since if this occurs it causes a serious drawback both in terms of time and financial resources, since not only the tooth but also the adaptor has to be replaced. It is necessary to take into account that the wear time of the teeth further depends on the revolutions at which the cutter head works, of the material it is working on, it being difficult to predict the life of the teeth. It also so happens that once the tooth is worn, and before the tooth bar begins to be worn due to the direction action on the terrain, the user perceives increased vibrations, notifying him or her that the tip of the tooth has already been consumed. Said vibration is due to the fact that as the tooth gradually wears, the section thereof gradually increases, the section of attack of the tooth on the terrain therefore being increasingly larger, causing the mentioned vibration since the optimal section for penetration has been consumed, such that when the entire section of the tip of attack has been consumed and the tooth bar is reached, said vibration is very large notifying the operators that it is necessary to replace the tooth.
Another object of the invention consist of the tooth being able to have between the front wear part and the nose for coupling to the adaptor, according to the previously defined inclined planes, a perimetral projection or flange or collar, the main purpose of which is to protect the contact area between the tooth and the adaptor from the material loosened during its dredging operation. Said collar also carries out three functions in the coupling:
Protecting the adaptor from wear through the deflectors in the upper and lower areas and which have been designed to redirect the flow of loosened material, preventing such material from rubbing or striking against the adaptor and therefore preventing the wear thereof, Preventing the loosened material from entering into the interlocking, acting as a plug and also reducing the entrance of material in the fastening or retaining system, and Making contact with the adaptor after prolonged wear through stoppers located in the upper and lower areas, said stoppers being thicker to resist the larger stresses to which it is subjected when contact with the adaptor is made, determining a third contact area between the tooth and the adaptor.
Said collar can have variable thicknesses along its length depending on the stresses to which it is subjected during the work of the coupling. Specifically, said collar has the thickest areas in its upper and lower area such that when contact is made, the reactions of the tooth bar on the collar exert a component directly opposing the applied force (Fc). In addition the middle area of the collar has a curve towards the tip of the tooth that adapts to the shape of the interlocking, according to the parallelism to planes S and I and allowing the contact areas to be closer to the tip of the tooth, this area being where the main contact areas, located close to said tip to also reduce the lever effect, are located. Said central areas have less thickness than in the upper and lower areas.
Another object of the invention is a tooth the nose of which is hollow, such that the amount of material that is worn out is reduced.
DETAILED DESCRIPTION OF THE DRAWINGS
To complement the description being made and for the purpose of aiding to better understand the features of the invention, according to a preferred practical embodiment thereof, a set of drawings is attached as an integral part of said description which show the following with an illustrative and non-limiting character:
FIG. 1 depicts a perspective view of a collarless tooth and an adaptor prior to their coupling.
FIG. 2 depicts a side elevational view of a collarless tooth and an adaptor prior to their coupling.
FIG. 3 depicts a perspective view of a collarless tooth.
FIG. 4 depicts the rear elevational view of a collarless tooth.
FIG. 5 depicts a side elevational view of a collarless tooth.
FIG. 6 depicts a plan view of a collarless tooth.
FIG. 7 depicts a side elevational view of a collarless tooth showing the inclined planes S and I.
FIG. 8 depicts a side elevational view of a tooth with a collar.
FIG. 9 depicts a front elevational view of a tooth with a collar.
FIG. 10 depicts a plan view of a tooth with a collar.
FIG. 11 depicts a cross-section of a solid tooth with a collar.
FIG. 12 depicts a cross-sectional view of a hollow collarless tooth.
FIG. 13 depicts a side elevational view of a collarless tooth.
FIG. 14 depicts a section, according to Y-Y, of the hollow collarless tooth of FIG. 13 .
FIG. 15 depicts a section, according to Z-Z, of the hollow collarless tooth of FIG. 13 .
FIG. 16 depicts a section, according to AC-AC, of the hollow collarless tooth of FIG. 13 .
FIG. 17 depicts a section, according to AA-AA, of the hollow collarless tooth of FIG. 13 .
FIG. 18 depicts a section, according to AB-AB, of the hollow collarless tooth of FIG. 13 .
FIG. 19 depicts a section, according to AE-AE, of the hollow collarless tooth of FIG. 13 .
FIG. 20 depicts a perspective view of an adaptor.
FIG. 21 depicts a view of an adaptor.
FIG. 22 depicts a rear view of an adaptor.
FIG. 23 depicts a section, according to AB-AB, of the adaptor of FIG. 22 , showing the inclined planes SA and IA.
FIG. 24 depicts a view of a collarless tooth and an adaptor coupled together.
FIG. 25 depicts a section, according to AE-AE, of the coupling between a collarless solid tooth and an adaptor shown in the FIG. 24 .
FIG. 26 depicts a collarless tooth and an adaptor coupled together showing the forces to which the assembly may be subjected and its reactions.
FIG. 27 depicts a collarless tooth in which the appendage of the nose of said tooth has a certain height along its entire length.
DESCRIPTION OF A PREFERRED EMBODIMENT
As observed in FIG. 1 , the invention object of the present application, tooth and adaptor for dredging, is formed by an interchangeable tooth 10 , an adaptor 20 coupled to a blade of a cutter head of a dredging machine, and a retaining member 30 responsible for assuring the connection between the tooth and the adaptor.
As can be observed in FIG. 3 and FIG. 20 , the tooth 10 consists of a front wear part 11 or tip of the tooth responsible for the task of eroding the terrain, in contact with the ground and stones, and in its rear part it has a projection or nose 12 intended for being housed in a housing or hollowing 24 arranged in the adaptor 20 .
FIG. 4 shows how the nose 12 of the tooth is formed by a lower base body 16 and an appendage 15 integrated in its upper surface, with a free end 14 attached at the end opposite to the front wear part, said nose 12 being separated from the wear part by the intersection of the upper surfaces of the appendage and the lower surface of the base body. More specifically, the gap between the wear part 11 and the nose 12 is determined by the two inclined planes S, I determined by said upper surfaces of the appendage and lower surface of the base body, such that the imaginary horizontal intersection line of both planes 1 1 is located in front of the vertical line (h max1 -h max2 ) determining the maximum height of the tooth 10 , located in the side opposite to that of the free end of the nose 14 . Said maximum height of the tooth H 3 is formed by the maximum height of the base body H 1 combined with the maximum height of the appendage H 2 .
According to a first vertical plane XY varying along the horizontal axis x, the base body of the nose, FIG. 13 to FIG. 19 , has a cross-section at the free end x 0 , according to a second vertical plane YZ, with a rectangular shape with rounded vertices such that the area of the cross-section, along the horizontal axis x, of the nose 12 gradually increases as the nose approaches the end for being attached to the wear part of the tooth, inclined planes S, I, specifically until the lower surface of the nose intersects the lower inclined plane I, after the point where the area of the cross-section along the horizontal axis x of the nose begins to decrease again until the intersection x 1 of the inclined upper S and lower I planes.
In addition, the section of the appendage 15 of the nose 12 of the tooth 10 has a trapezoidal cross-section, its lower base being narrower than the upper surface of the base body of the nose 16 and centered with respect to said base body 16 , such that the height of said appendage is nil in an area close to the free end 14 of the nose x 0 , and its height gradually increases until reaching a maximum height H 2 , at which point the upper surface of said appendage 15 and therefore of the nose 12 intersects the upper inclined plane S of separation with the wear part of the tooth 11 , the height of the appendage decreasing after this point until reaching the intersection x 1 of the upper S and lower I inclined planes. Said appendage 15 could also not have nil height at the free end of the nose 14 (see FIG. 27 ), or not be centered with respect to the base of the nose 16 .
The lateral sides 151 , 152 of the successive cross-sections of the appendage 15 and the upper side 121 , 122 of the successive cross-sections of the base of the nose 16 of the tooth 10 form an angle varying between 45° and 180°, preferably between 45° and 135°, and even more preferably greater than 90°.
According to the foregoing, the description provides that the nose of the tooth 10 has a lower base body 16 , with a section of at least four sides (a, b, c, d) with rounded vertices and with an upper surface 120 and a lower surface 123 . On said lower base body 16 there is an upper appendage 15 with an upper surface 153 and a lower surface 154 , and with a trapezoidal section the lower base 154 of which is larger than the upper base 153 and the lower base 154 is in turn narrower than the upper surface 120 of the lower base body 16 and is centered with respect to the upper surface 120 of the lower base body 16 . The nose also has a free end 14 , opposite to the front wear part or tip 11 , and an end opposite to the mentioned free end and attached to the tip 11 of the tooth 10 .
The nose of the tooth and its section, as well as that of the area of attachment with the front part of the tooth or tip of the tooth, is determined by the progressive gap of the upper 120 and lower 123 surfaces of the lower base body 16 starting from a point close to the free end 14 of the nose 12 and therefore increasing the section of said base body 16 in the direction of the tip of the tooth 11 , until defining a maximum gap H 1 corresponding with the maximum height H 1 ) of the lower base body 16 . The upper 153 and lower 154 surfaces of the appendage 15 also progressively separate from one another from a point close to the free end 14 of the nose 12 , thus increasing the section of said appendage 15 in the direction of the tip of the tooth 11 , until determining a maximum gap H 2 defining the maximum height H 2 of the appendage 15 . The union of the maximum heights H 1 , H 2 of the lower base body 16 and of the appendage 15 , determine a line of maximum height H 3 of the nose of the tooth 12 , such that after said line of maximum height H 3 the upper surface 153 of the appendage 15 and the lower surface 123 of the lower base body 16 begin to converge towards the tip 11 of the tooth 10 until the union of both surfaces 153 , 123 , the union line of both surfaces 11 being located on the side of the wear part of the tooth 11 and in front of the line of maximum height H 3 . Said maximum height is located at a balance point between good penetration of the system, which as mentioned depends on the total height of the nose, and of the resistance of the system, which depends on the stresses to which it is subjected.
The adaptor, FIG. 20 , is formed by a body having a coupling 21 at one end to be attached to a blade of the cutter head of a dredging machine and at the opposite end it has a hollowing or housing 24 for receiving the rear projecting part or nose 12 of a tooth 10 , which is inserted in said housing 24 . The inner surfaces, FIG. 22 , of said housing 24 of the adaptor 20 are complementary to the surfaces of the nose 12 of the tooth 10 . In other words, said housing 24 is formed by a lower base hollow 22 and an inverted T-shaped appendage in its upper surface 25 in the opening 28 of the housing 24 coinciding with the free end thereof. The shape of said free end or opening 28 is defined by two inclined planes, an upper plane SA and another lower plane IA, which correspond with the upper surface of the hollow appendage and with the lower surface of the base hollow of the nose, intersecting at their intersection line (or point) 12 formed by the infinite points x 3 of the intersection of the planes, such that the intersection line 1 2 of both planes is in front of the line (h max1 -h max2 ) determining the maximum height A 3 of the hollowing 24 , as shown in FIG. 23 .
As previously described, the inner surfaces are complementary to that of the nose of the tooth, therefore the infinite sections of said housing are complementary to the infinite sections of the nose of the tooth such that according to a first vertical plane XY, which varies along the horizontal axis x, the hollowing has at the bottom 26 of the hollowing 24 , opposite to the opening 28 , a cross-section, according to a second vertical plane YZ, with rectangular shape with rounded vertices, such that the area of the cross-section of the hollowing 24 gradually increases as it approaches the opening 28 of the hollowing 24 (planes SA, IA), specifically until the lower side of the hollowing 24 intersects with the lower inclined plane IA, such that after this point the area of the cross-section of the hollowing 24 begins to decrease again until the intersection x 3 of the inclined upper SA and lower IA planes.
Likewise the section of the upper appendage 25 of the hollowing 24 has a trapezoidal cross-section, narrower than the base of the hollowing 22 , and centered with respect to same 22 , such that the height of said appendage is nil in an area close to the bottom of the hollowing 26 , and its height gradually increases until the upper surface of said appendage 25 intersects with the upper inclined plane SA of separation, the height of the appendage 25 decreasing after this point until reaching the intersection x 3 of the inclined upper SA and lower IA planes. Likewise, the upper appendage 25 may not end in its area close to the bottom of the hollowing 26 with nil height, but rather with certain height, and it could also not be centered with respect to the base of the hollowing 22 .
Obviously as in the nose 12 of the tooth 10 , the lateral sides 251 , 252 of the successive cross-sections of the appendage 25 and the upper side 221 , 222 of the successive cross-sections of the base of the hollowing 22 forms an angle with one another varying between 45° and 180°, preferably between 45° and 135°. Even more preferably said angle is greater than 90°.
In other words, the adaptor 20 has at the end opposite to that of the coupling 21 a hollowing or housing 24 for receiving the rear projecting part or nose 12 of a tooth 10 , which is completely inserted in said housing 24 . Said housing 24 is formed by a lower base hollow or hollowing 22 having a section of at least four sides with rounded vertices, an upper surface 220 and a lower surface 223 , arranging on said upper surface a hollow upper appendage 25 forming the housing 24 of the nose 12 of the tooth 10 . Said hollow appendage 25 is formed by an upper surface 253 and a lower surface 254 , and it also has a trapezoidal section the lower base 254 of which is larger than the upper base 253 and such lower base 254 is in turn narrower than the upper surface 220 of the lower base hollow 22 , said hollow appendage 25 being centered with respect to the upper surface 220 of the lower base body 22 . The housing 24 has an opening 28 at the end opposite to the end for coupling the adaptor to the, and an end opposite to that of the opening 28 forming the bottom 26 of the housing 24 , and therefore located close to the coupling to the blade. The housing 24 of the adaptor 20 is also determined by the upper 220 and lower 223 surfaces of the lower base hollowing 22 which progressively separate from one another from a point close to the bottom of the hollowing 26 of the adaptor 20 , such that the section of said base hollowing 22 gradually increases in the direction of the opening 28 of the adaptor 20 until a maximum gap A 1 is defined, corresponding with the maximum height A 1 of the lower base hollowing 22 . The upper 253 and lower 254 surfaces of the hollow upper appendage 25 progressively separate from one another from a point close to the bottom of the hollowing 26 of the adaptor 20 , the section of said hollow appendage 25 thus increasing in the direction of the opening 28 of the adaptor 20 , until determining a maximum gap A 2 defining the maximum height A 2 of the hollow appendage 25 . The union of both heights A 1 , A 2 of the lower base hollowing 22 and of the hollow appendage 25 determine a line of maximum height A 3 of the opening 24 of the housing 24 of the adaptor 20 . After said line of maximum height A 3 the upper surface 253 of the hollow appendage 25 and the lower surface 223 of the lower base hollowing 22 begin to converge in the direction opposite to that of the bottom of the hollowing 26 until the union of both surfaces 253 , 223 , the union line of both surfaces 12 being located on the opposite side of the bottom of the hollowing 26 and in front of the line of maximum height A 3 of the opening 28 of the hollowing 24 of the adaptor 20 .
As shown in FIG. 24 and FIG. 25 , both members are coupled together by inserting the nose 12 of the tooth 10 into the housing 24 of the adaptor 20 , the different complementary surfaces of the nose 12 and of the housing 24 coming into contact with one another.
At the same time the adaptor 20 has been installed through its coupling 21 in the blade or propeller of the cutter head of the dredging machine, the tooth 10 is installed, using for that purpose a preferably hammerless retaining member 30 , i.e. a member that does not require the action of a mallet or hammer for removing it from or inserting it in the housings intended for such purpose in the tooth and in the adaptor. The retaining system is vertical, being inserted and removed through the upper part of the tooth and of the adaptor, traversing the nose 12 of the tooth 10 and the body of the adaptor 20 through respective through holes 13 , 23 .
Once the assembly is put together and during the working operations, the tooth 10 is subjected at its tip 11 to an upward perpendicular force (Fc) in the lower side of the tip of the tooth 11 , less commonly being able to be subjected to a force normal Fs to the tip of the tooth due to the swell of the boat, causing a series of stresses and reactions in the coupling between the tooth 10 and the adaptor, specifically in the contact surfaces between both.
The first contact area between both is formed by the two surfaces, both in the tooth and the adaptor, coming into contact with one another, specifically those which are located on both sides of the appendage 15 of the nose 12 of the tooth 10 or of the appendage 25 of the hollowing 24 of the adaptor 20 , i.e. surfaces 121 , 122 in the tooth 10 and surfaces 221 , 222 in the adaptor 20 . This first contact area, which is very close to the tip of the tooth 11 , generates self-tightening reaction Rx 2 preventing the tooth 10 from being ejected from the adaptor 20 due to the stresses to which it is subjected. It is also possible that there is only one first contact surface between the tooth 10 and the adaptor 20 , for example in the case in which the appendage 15 of the nose 12 of the tooth 10 is not centered with respect to the base of the nose 16 of the tooth 10 .
A constructive alternative in the tooth 10 consists of arranging a collar or flange 40 therein (see FIG. 8 to FIG. 11 ), located on the perimeter of the tooth and coinciding with the gap previously defined between the front part of the tooth or tip 11 thereof and the beginning of the nose 12 of the tooth 10 . The thickness or width of said collar 40 varies depending on the area of the tooth it surrounds depending on the stresses to which said area is subjected.
Another feature of the tooth 10 object of the present invention is that the nose 12 of the tooth 10 has a hollowing or cavity 50 to reduce the weight of the tooth without affecting its mechanical features (see FIG. 12 ).
It should be mentioned that the adaptor has at least one groove 27 in its contact area with the tooth for inserting a tool and aiding in removing the tooth once the retaining member arranged between both has been removed.
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The tooth and adaptor for dredging machines object of the present invention relates to a tooth or wear member which, attached to an adaptor or adaptor member, creates an assembly the purpose of which is to deepen and clean the beds of ports, rivers, channels, etc., removing therefrom sludge, stones, sand, etc., the adaptors being attached to the blades of the propellers and thus forming the cutter head of the dredging machine. The constructive features of the coupling between the tooth and the tooth bar or adaptor allow making better use of the cutting material of the tooth and a simple and quick replacement thereof in the adaptor, between other advantages.
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This application is a Continuation of U.S. patent application Ser. No. 10/084,232, filed Feb. 28, 2002, which claims priority to U.S. Provisional Patent Application No. 60/272,433, filed Feb. 28, 2001.
FIELD OF THE INVENTION
The present invention relates to dental devices for treating snoring and sleep apnea, more particularly the present invention relates to devices for positioning and restraining the tongue of a person.
RELATED ART
Many studies have been undertaken to better understand snoring and sleep apnea. It has been well documented that snoring occurs while breathing through the mouth during sleep when the tongue partially blocks the airway. Thus, one way to cure or mitigate snoring is to hold the tongue in a forward position, whereby airway blockage cannot occur. Although generally merely an annoyance to those other than the person snoring, it is known that in certain instances airway blockage will become complete resulting in apnea, i.e., a cutting off of the air supply to the lungs and thus decreasing the amount of oxygen carried by the blood to the brain.
Sleep apnea not only interrupts a persons sleep patterns resulting in chronic fatigue, it can also cumulatively cause brain damage. Therefore, for many persons, reducing or eliminating snoring is a serious matter. Sleep apnea can be classified into three basic categories, 1) Central apnea, 2) Obstruction Apnea, and 3) Mixed Apnea.
Central apnea is classified as a stoppage of airflow because inspiratory efforts temporarily cease. The airway remains open and the chest walls make no effort to create airflow. The potential medical effects which may result due to central apnea are: encephalitis, brainstem neoplasm, brain stem infarction, poliomyelitis, spinal cord injury, and cervical cordoromy.
Obstruction apnea is classified as the cessation of airflow due to total airway collapse despite a persistent effort to breath. An obstruction in the upper airway can occur in three areas which are, a) Nasopharyngeal, b) Oropharyngeal, and c.) Hypopharyngeal regions.
Mixed apnea is classified as a combination of central and obstructive apnea usually beginning with a central episode being immediately followed by an obstructive one.
Many devices have been developed to address the problem of sleep apnea. One such device is Continuous Positive Airway Pressure (CPAP) this technique involves wearing a mask tightly over the nose during sleep. Pressure from an air compressor forces air through the nasal passages and into the airway. This forced air creates a pneumatic splint, keeping the airway open and allowing the person to sleep normally. Though this technique is highly effective, this therapy is not for everyone. In fact, daily compliance by persons using CPAP is less than 50%. Furthermore, this technique has many drawbacks some of which are that it is uncomfortable, inconvenient, restricts the person's motion and dries out the mucosa. Further still, there is also a real concern of having reduced cardiac output and renal function.
Another approach to treating apnea is to surgically alter the person's breathing passages. The most effective surgical procedure for treating apnea is a tracheostomy which enjoys a 100% success rate because it completely bypasses all of the sites of the upper airway obstruction, although it is rarely accepted by persons because many cannot accept the idea of permanent tracheostomy. A number of complications emerge with time, some of which are tracheal site infection, physiological problems, granuloma formation, chronic irritation, uncontrolled secretions, bronchial infections and eventual stenosis.
A different surgical approach is nasal reconstruction. Many times a nasal obstruction causes a person to mouth breath, when you breathe through your mouth the mandible rotates back and allows the base of the tongue to drift posteriorly and block the airway.
A still further surgical method that may be employed is uvulopalatopharyngoplasty (UPPP). This procedure enlarges the air space by excising redundant soft tissue of the palate, uvula, tonsils, posterior and lateral pharyngeal walls. This procedure can be quite successful at stopping snoring, most studies indicate that this method is approximately 50% effective.
In addition to the techniques and devices above, there is still another series of devices that have been developed to treat sleep apnea. These devices can be classified as dental appliances. Dental appliances may be in the form of a soft palate lift device and tongue retention devices.
Many types of tongue holding devices are known. For example, metallic or hard plastic clips are disclosed in the art, e.g., in U.S. Pat. No. 4,198,967-Dror and U.S. Pat. No. 3,809,094-Crook. However, these devices risk pain and injury to the tongue, and are particularly unsuited to self-administration. A less traumatic device designed for self-administration and for extended periods of use (i.e., overnight) is disclosed in U.S. Pat. Nos. 4,169,473 and 4,304,277, both to Samelson. The device disclosed in the Samelson patents evacuates air from a tongue holder and uses an imperforate structure in a device that is positioned by holding both dental arches in a locked position. Such a device, however, is detrimental to the normal bite relationship of the dental arches since it distorts the relationship of the upper and lower jaws. U.S. Pat. No. 4,196,724-Wirt discloses a tongue receptacle having a rearwardly converging configuration into which the tip of the tongue is wedged. However, the device disclosed in the Wirt patent causes pain, swelling and edema by concentrating an applied vacuum to a small area of the tip of the tongue. Furthermore, the requirement for an attachment to a vacuum-producing device such as the disclosed elastically contractible bellows is cumbersome and annoying to a sleeping user. U.S. Pat. No. 4,676,240-Gardy proposes a device that engages either the teeth or the gum arches to anchor the device in position. The tongue is received in a vacuum chamber and displaces the air therein. The tongue is sealed in the chamber by internal sealing ridges located on the inside of the vacuum chamber.
Another such tongue retention device is described in U.S. Pat. No. 5,373,859 Forney and shown in FIG. 6 . The Forney device, as illustrated in FIG. 6 , is designed to retain the tongue in a normal or extended position without undue discomfort for an extended period of time by holding the tongue securely in a housing by means of vacuum created within the device. The housing may then be positioned by holding it with the fingers or, in another embodiment, by an integral flange which rests against the face and permits self-application. The device uses a housing that is designed to form a seal with the tongue at its proximal portion, and diverging walls within the housing to limit other areas of contact with the tongue. The device also preferably uses an opening that is arcuate shaped and includes a soft conformable extension portion.
Shortcomings of these devices are that the device extends beyond the person's teeth and into the oral cavity. Additionally, the device cannot be custom fitted to each individual's anatomy because any modifications to the distal portion of the device will reduce the overall vacuum effect. Still further, many of these devices are constructed of thick non-yielding materials that when in use prove to be very uncomfortable to be worn for extended periods of time because the device will not conform to the user's anatomy. Another shortcoming of many of these devices is that the portion of the device adapted to receive the person's tongue are not designed having a limited volume, thus the user may insert a greater amount of tissue into the device therefore resulting in great discomfort to the user. Lastly, many of presently available devices further include stiffening means disposed within the device, many times the stiffening means is in the form of ribs disposed within the area adapted for receiving the person's tongue, thus when a vacuum is drawn to retain the device upon the person's tongue these stiffening ribs prove to be uncomfortable.
There remains a need for a device that can position a person's tongue in an extended manner to treat sleep apnea. It is therefore an object of this invention to provide a pliable device which comfortably holds a tongue using vacuum forces.
It is another object of the present invention to provide a device which may be comfortably worn while sleeping and which does not extend into the oral cavity of the person.
It is a further object of the present invention to provide a device which may be easily cleaned after use.
It is still a further object of the present invention to provide a device for retaining a person's tongue in an extended manner where the device does not require great manual dexterity to utilize.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with one aspect of the present invention there is provided a device for retaining a tongue in a predetermined position, the device comprising, a flange having a first and second surface, the flange further including a protrusion extending from the first surface of said flange. The device further including an aperture formed through said first and second surfaces of said flange, wherein the protrusion covers the aperture, whereby the protrusion forms a hollow chamber, the hollow chamber being accessible through the aperture from the second side of the flange.
In accordance with another aspect of the present invention there is provided a device for retaining a tongue in a predetermined position, the device comprising, a flange having a first and second surface, an aperture disposed within the flange wherein the aperture further includes walls extending from the first surface of a flange, the walls forming a bulb protruding from the first surface of the flange, wherein the bulb forms a chamber in communication with the aperture and being adapted to receive a tongue.
In accordance with another aspect of the present invention there is provided a method of retaining a tongue in a predetermined position, the method comprising, forming a vacuum within a tongue retention device by squeezing the walls of a protrusion extending from a flange of the tongue retention device, inserting a tongue through an aperture formed in the flange, wherein the tongue is received by the protrusion, releasing the walls, thereby forming a vacuum within the protrusion; and positioning the tongue retention device between a user's lips and teeth.
DETAILED DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to preferred embodiments illustrated in the accompanying drawings, in which like elements bear like numerals; and wherein;
FIG. 1 is a top view of the tongue retention device of the present invention;
FIG. 2 is a front view of the tongue retention device illustrating a flange and a protrusion that extends from said flange;
FIG. 3 is a back view of the tongue retention device illustrating the aperture formed in the flange, wherein the aperture is in communication with the protrusion;
FIG. 4 is a side view of the tongue retention device;
FIG. 5 is a perspective side view illustrating the flange, protrusion, and aperture;
FIG. 6 is an illustration of a prior art tongue retention device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now FIG. 1 there is shown a tongue retention device 10 of the present invention. The tongue retention device 10 includes a flange 14 , an aperture 16 and a bulb 18 . The tongue retention device 10 is preferably formed as a unitary body wherein a soft pliable material is utilized in its construction. Such materials which may be utilized for the construction of tongue retention device 10 are polyvinylchloride, polyethylene, urethane, silicon or other similar bio-compatible materials. One such material that may be used to construct tongue retention device 10 of the present invention is referred to as “Sta-Vac sheet resin” which is available from a number of commercial manufacturers such as Buffalo Dental Manufacturing Company, 99 Lafayette Drive, Syosset, N.Y. 11791 USA.
The tongue retention device 10 may be formed having a constant thickness across it's entire cross section or alternatively, the cross sectional thickness may be varied according to design needs, preferably the tongue retention device 10 is formed having a thickness between about 0.010 inches and about 0.060 inches, more preferably between about 0.025 inches and about 0.040 inches.
As shown in FIGS. 1-5 tongue retention device 10 of the present invention may be formed by blow molding, injection molding, casting, vacuum forming or similar manufacturing procedures which will result in the formation of a one piece body.
Referring now to FIGS. 1 , 3 , and 5 there is shown the tongue retention device 10 of the present invention. As shown, the tongue retention device 10 includes a bulb 18 . The bulb 18 is unitarily formed with flange 14 thereby forming a one piece tongue retention device 10 as described in detail above. As shown in FIGS. 4 and 5 the bulb is formed of walls 19 extending from the first surface 13 of the flange 14 forming the bulb 18 . Additionally, as indicated by reference numeral 20 , the bulb 18 forms a smooth transition with the first surface 13 of flange 14 thereby eliminating any sharp edges or surfaces which may contact the person's skin. Still further, the interior surfaces of bulb 18 are formed having a smooth surface finish. This smooth surface finish promotes easy cleaning in that bacteria cannot become lodged within any creases or openings in the surface. Additionally, the smooth surface provides a degree of comfort to the user.
As shown in FIGS. 1-5 the bulb 18 is formed being adapted to receive a person's tongue. The bulb 18 is also designed having a pre-determined volume such that only a pre-determined amount of the person's tongue will be received by the interior of the bulb 18 . As shown in FIG. 3 , the aperture 16 is designed having an elongated shape having radiused ends whereby the aperture may receive a person's tongue. The proximal area 17 A of the aperture 16 is radiused accordingly so that the area 17 A provides a smooth transition between the aperture 16 and the second surface 12 . The distal area 17 B (not shown) is also radiused to provide a smooth transition between the aperture 16 and the inner surface of the walls 19 of the bulb 18 . In addition to the features above, the thickness of the material utilized to construct the tongue retention device 10 provides a sufficient amount of vacuum force within bulb 18 to retain the person's tongue therein but not a force that is to great as to cause pain and discomfort to the person.
Referring now to FIGS. 1-6 as shown, the flange 14 of the tongue retention device 10 further includes a curved portion 30 . The curved portion 30 may be adjusted to fit the user's jaw line so that during use the device comfortably fits between the user's teeth and lips. Still further, the overall size of the flange 14 may be adjusted by trimming to accommodate the sizes of different person's mouths. This feature also allows for the manufacture of a single size of the tongue retention device 10 thereby lowering overall production costs of the device. Alternatively, the tongue retention device 10 may be manufactured having multiple size variations in which both the flange and volume of the bulb 18 are adjusted accordingly.
In use, the bulb 18 of the tongue retention device 10 is gripped by the user and the user then places the tip of their tongue into the aperture 16 and the bulb 18 is squeezed to reduce the air volume within the bulb 18 . By squeezing the bulb 18 , air is forced out of the bulb past the person's tongue, when the force is released from the bulb 18 , due to the resiliency of the material the bulb tries to return to its uncompressed shape. In doing so, a vacuum is formed within the bulb because the tongue inserted into the aperture 16 provides a seal between the interior of the bulb 18 and the external atmospheric pressure. Thus, the tongue retention device 10 is thereby retained on the person's tongue. Alternatively, the person may insert their tongue through aperture 16 and into the bulb 18 , after insertion they may then affix the tongue retention device by sucking back on the device and drawing air out of the bulb 18 thereby forming a vacuum therein. In utilizing either method, the user does not have to have a great deal of manual dexterity to affix the device to their tongue.
After affixing the tongue retention device to their tongue, the device is then positioned within the mouth, such that the second surface 12 of the flange 14 abuts the person's teeth and the first surface 13 of the flange 14 rests just behind the person's lips. Thus, in use, the tongue retention device 10 does not extend into the oral cavity of the person. Additionally, the tongue is accurately held into a pre-determined position. The position can be accurately reproduced with each use of the device, therefore the user is not required to adjust any parameter of the device between uses.
If needed, as described above, the overall size of the flange may be easily adjusted to accommodate a wide variety of geometries. For example, the flange may be trimmed down to fit a smaller mouth, or the curved portion 30 may be heat formed into a different curvature that may be more comfortable. In addition to providing treatment for sleep apnea, the tongue retention device of the present invention may also be utilized in applications regarding the treatment of bruxism (the grinding of teeth while sleeping) and thereby TJM muscle point for both those with teeth and without teeth.
Throughout the description above many advantages over the prior art are described. Such advantages include the limited volume of the bulb 18 thereby limits the volume of the tongue that will be retained by the tongue retention device 10 . Still further, the tongue retention device 10 is formed of a material having a desired thickness such that overall the device remains pliable and resilient thereby resulting in a tongue retention device that is both comfortable and easy to use. Still further the design features of the present invention allow the tongue retention device 10 to be custom fitted for each application, thereby promoting comfort to the person while reducing overall manufacturing costs, alternatively, the design of the tongue retention device 10 allows for manufacture of various sizes. Also, unlike presently available devices, the tongue retention device 10 of the present invention does not protrude into the oral cavity. Lastly, the tongue retention device 10 of the present invention may be utilized in other applications such as the treatment of bruxism.
The foregoing description of certain preferred embodiments is set forth for the purpose of illustrating the principals of the invention. Since numerous alternative uses, modification 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 above, in the drawings and within the claims. Thus, all suitable modifications and equivalents that may be reported to will fall within the scope of the invention, which is defined by the appended claims.
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A device for retaining a tongue in a predetermined position, the device comprising, a flange having a first and second surface, the flange further including a protrusion extending from the first surface of the flange; and an aperture formed through the first and second surfaces of the flange, wherein the protrusion covers the aperture, whereby the protrusion form a hollow chamber, the hollow chamber is accessible through the aperture from the second side of the flange.
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TECHNICAL FIELD OF THE INVENTION
This invention relates in general to the field of deformable mirror devices. More particularly, the present invention relates to a method and apparatus for optically projecting at least two rows of stacked DMD images such that the projected image is a single continuous image.
BACKGROUND OF THE INVENTION
A printing system has been designed which takes advantage of a spatial light modulator device to create a very simple exposure unit. The system uses a conventional light source such as a tungsten halogen light, and which is focused onto a deformable mirror device (DMD) consisting of a row or rows of individually deformable mirrors constructed on a single substrate.
The DMD is arranged in conjunction with a lens such that in the undeflected state, light reflecting from each mirror has a reflection angle such that the light is directed away from the remaining elements of the printing system. When a particular mirror is otherwise deflected, the angle of light reflection changes, and the light is then passed through the remaining system. The reflected light may, for instance, be directed to a photo receptor drum of a standard xerographic print process.
Present semi-conductor manufacturing processes are able to achieve DMD widths of up to 20 millimeters, containing approximately one thousand individual mirrors. These densities result in DMDs capable of illuminating a three-inch long strip at approximately 300 dots per inch (dpi) which is letter quality. Most printing applications, however, use formats wider than three inches. This requires a system designer to either lengthen the traditional 20 millimeter DMD row or to magnify the projected array such that a print density of less than 300 dpi results. The first alternative, producing an extended DMD, though theoretically possible, is prohibitively expensive. Producing a long DMD increases fabrication complexity of the DMD, poses difficult problems of uniform illumination, and often results in a non-uniform image even when properly illuminated. The second alternative, reducing the pixel print density, is not acceptable in those applications requiring letter quality print output.
Therefore, a need has arisen for a deformable mirror device system which is capable of illuminating an extended strip and which is easy to fabricate, illuminate and which results in uniform projections.
SUMMARY OF THE INVENTION
In accordance with the present invention, a deformable mirror device system is provided which substantially eliminates or reduces disadvantages and problems associated with prior deformable mirror devices.
An optical system is disclosed that combines and projects two images into a single continuous image. More specifically, an optical guide is described that accomplishes the combination-projection function. In one embodiment, the optical guide takes the form of a central silvered kite prism with tilted left and right prisms. In another embodiment, the optical guide consists of a semi-transparent beam splitter and a set of tilted reflecting surfaces. In yet another embodiment, the optical guide comprises an upper and lower pair of modified rhomboidal prisms.
It is one technical advantage of the disclosed invention to provide a simple system and method of creating wide DMD images with currently available narrow DMDs.
It is another advantage to produce wide DMD images with the high resolution necessary for high quality printing applications without increasing the physical width of the device.
It is a still further technical advantage of the invention to provide a wide resultant display from a plurality of parallel offset DMD pixel arrays.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects, features, and technical advantages, as well as others, of the invention will be more apparent from the following description of the drawings in which like numbers refer to like members and in which:
FIG. 1 schematically shows a first embodiment of the disclosed invention;
FIGS. 2A and 2B depict, respectively, an above and forward view of the optical system disclosed in FIG. 1;
FIG. 3 depicts a second embodiment of the disclosed invention;
FIG. 4 depicts a third embodiment of the disclosed invention;
FIG. 5 depicts a cross-sectional view of the optical system depicted in FIG. 4;
FIGS. 5, 6 and 7 depict forward and rear views of the optical system depicted in FIG. 4;
FIG. 8 shows an above view of the optical system shown in FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts one embodiment of an optical system designed to project the images of two separate deformable mirror device ("DMD") rows 18, 20 onto screen 28 or plane such that the projected image forms a single continuous line 31.
Light source 10 illuminates DMD 12 through focusing lenses 14 and 16. DMD 12 contains two (or more) rows of individual mirror elements 18 and 20. Each of these rows contains approximately 1,000 small individual mirrors which may be electronically controlled by signals (not shown). Individual mirror rows 18 and 20 are shown on a single integrated chip substrate. Rows 18 and 20, however, may be on separate chips located generally near one another. Light from light source 10 reflects off rows 18 and 20 through imaging lens 22 along optical axis 24. DMD 12 is generally aligned so row 18 is above optical axis 24 and row 20 is below optical axis 24. Optical system 26 separates the images from rows 18 and 20 into a left and right channel, raises or lowers each channel as necessary and projects the two channels onto screen 28. By selecting the components of optical system 26 and imaging lens 22, the final size of the projected image may also be adjusted. The image on screen 28 forms a long single image 31 comprising a left half 30 and right half 32 corresponding to DMD rows 18 and 20 respectively. The operation of a typical DMD device can be seen in copending patent application entitled, "Spatial Light Modulator Printer and Method of Operation", Ser. No. 07/454,568, filed Dec. 21, 1989, which application is hereby incorporated by reference herein.
In one embodiment, optical system 26 comprises a central channel separator 34 aligned along axis 24 and left and right prisms 36 and 38. Channel separator 34 may comprise a set of four mirrors or an optical prism with four silvered surfaces. Prisms 36 and 38 are right angle isosceles prisms with each right angle milled off for packaging convenience.
Light rays reflected off DMD rows 18 and 20 enter imaging lens 22 and then are separated into left and right channels by the faces of channel separator 34 generally facing imaging lens 32. The separated images are then reflected outwards to prisms 36 and 38 where they are raised and lowered respectively and then redirected towards the two surfaces of channel separator 34 facing screen 28. The images are then projected from these latter two surfaces onto screen 28. By carefully choosing imaging lens 22, one contiguous image of DMD rows 18 and 20 can be projected to screen 28.
FIG. 2A more clearly shows the positioning of prisms 36 and 38 and channel separator 34. Channel separator 34 may consist of four mirrored surfaces, two modified silvered right angle prisms cemented together, or a single silvered kite prism, all having interior angles as indicated. Channel separator 34 has a length L1. Right angle prisms 36 and 38 have a hypotenuse length L2 and interior angles as indicated. Prism 36 and 38 are separated from channel separator 34 by distances X1, X2, X3, X4 and X5 as indicated in the drawing. The distances are measured at the base of the elements.
FIG. 2B depicts optical system 26 as viewed from imaging lens 22 (not shown) towards screen 28 (not shown). Prisms 36 and 38 are not mounted perpendicular to the base of channel separator 34. Prism 36 is tilted inwards towards channel separator 34 at an angle a. Prism 38 is tilted away from channel separator 34 at an angle b. Prisms 36 and 38 may be mounted, for example, by introducing shims between their base and a standard reference plane or by removing an angled portion of their respective bases during the manufacturing process.
It should be noted that for certain configurations the outside prisms may be positioned with a symmetrical tilt inward toward kite prism 34.
DMD rows manufactured on the same chip are typically 14 mm long by 0.036 mm tall and may be separated from one another by 6 mm. To combine and project such a combination onto a screen or surface approximately 250 mm distant with a magnification of 6.3×, the following dimensional parameters may be used:
Imaging lens
focal length=50 mm
diameter=35 mm
X1=44.5 mm
X2=35 mm
X3=35 mm
X4=44.5 mm
X5=1 mm
H=44 mm
Angle a=1.5 degrees
Angle b=1.5 degrees
L1=64 mm
L2=64 mm
It should be understood that the particular embodiment associated with the above parameters is presented solely for purposes of teaching the present invention and should not be construed to limit the scope of the present invention to this or any embodiment.
FIG. 3 depicts a second embodiment of the disclosed invention to combine images from DMD rows 18 and 20. Light source 10 reflects off DMD 12 after passing through focusing lenses 14 and 16. The reflected image is then directed to a beam splitter 40 after being reflected off a plane mirror 42. Beam splitter 40 is partially reflective, partially transparent to electromagnetic radiation emitted by light source 10 causing a portion of each of the DMD images to be reflected towards angled first surface mirror 44 and transmitted towards angled first surface mirror 46. Beam splitter 40 is located at a 45° angle to optical axis 24 created by imaging lens 22. Mirrors 44 and 46 are aligned at approximately a 90° angle to one another as indicated in the drawing. It should be understood that mirrors 44 and 46 may take numerous forms, including plane mirrors and silvered prisms. The reflective faces of prisms 44 and 46 are tilted away from and towards beam splitter 40 respectively. After the separated image is raised and lowered by prisms 44 and 46 it is recombined at beam splitter 40 and transmitted to screen 28 via imaging lens 22. By carefully choosing imaging lens 22, one connected image of DMDs 18 and 20 appear on screen 28.
FIG. 4 depicts a third embodiment of the disclosed invention. Again light source 10 illuminates DMD 12 after passing through focusing lenses 14 and 16. The reflected images from rows 18 and 20 are focused by imaging lens 22 along optical axis 24. Rhomboidal prisms 48 and 50 separate the reflected image into an upper and lower channel, lower the upper channel and raise the lower channel, and recombine the two channels into images 30 and 32 on screen 28. By carefully choosing imaging lens 22, one connected image of DMDs 18 and 20 appear on screen 28.
FIG. 5 shows a cross-sectional view of rhomboidal prisms 48 and 50 and imaging lens 22. Imaging lens 22 inverts the reflected image from DMD rows 18 and 20 before the images enter rhomboidal prisms 48 and 50. Rhomboidal prisms 48 and 50 are aligned such that the surface formed by the upper surface of prism 50 and the lower surface of prism 48 ("boundary plane") coincides with optical axis 24 and is generally parallel to DMD rows 18 and 20. The surfaces of prisms 48 and 50 are angled to recombine images of DMD rows 18 and 20 into a single continuous row.
FIG. 6 depicts a view of prisms 48 and 50 as viewed from screen 28. Imaging lens 22 is partially visible.
FIG. 7 depicts prisms 48 and 50 as viewed from DMD 12. Imaging lens 22 is positioned between DMD 12 and prisms 48 and 50.
FIG. 8 shows more clearly how rhomboidal prisms 48 and 50 each are comprised of two smaller rhomboidal prisms joined together. Individual prisms comprising rhomboidal prisms 48 and 50 are constructed with exterior faces 52 and interior faces 54. Interior surfaces 54 are vertical with respect to the boundary plane. Exterior surfaces 52 are angled to cause the beam displacement as depicted in FIG. 5. FIGS. 6 and 7 show a typical inclination of these surfaces towards the boundary plane.
The above assemblies may be connected in series fashion to provide a second or third combining function. For example, four stacked DMDs could be combined with two optical systems to quadruple the size of the projected image.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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An optical system is described for combining separate deformable mirror device images into a single image. The resulting image is a single continuous image comprising left and right halves corresponding to the original individual images. The system is particularly useful for presenting DMD images to the printing drum of a xerographic process for letter quality documents. The combined image width allows a substantially greater printing width than was previously possible.
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This application is a continuation-in-part of U.S. patent application Ser. No. 768,784, filed Aug. 23, 1985 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to the art of papermaking, and particularly to a method of treating starch-containing paper product at high temperature to improve its properties, including dry and wet stiffness and wet tensile strength.
2. Description of the Prior Art:
In the art of papermaking, it is customary to subject felted fibers to wet pressing and then to drying on heated rolls.
There is currently considerable interest in improving various properties of paper and boards. Quantifiable paper properties include: dry and wet tensile strength, folding endurance, stiffness, compressive strength, and opacity, among others. Which qualities should desirably be enhanced depends upon the intended application of the product. In the case of milk carton board, for example, stiffness is of utmost importance, whereas for linerboard three qualities of particular interest to us are strength, folding endurance, and high humidity compression strength.
All of these properties can be measured by well-known standard tests. As used herein, then, "wet strength" means wet tensile strength as measured by American Society for Testing and Materials (ASTM) Standard D829-48. "Folding endurance" is defined as the number of times a board can be folded in two directions without breaking, under conditions specified in Standard D2176-69. "Stiffness" is defined as flexural rigidity and is determined in a standard TAPPI test as the bending moment in g-cm at a fifteen degree deflection angle. "Linerboard", is a medium-weight paper product used as the facing material in corrugated carton construction. Kraft linerboard is linerboard made according to the kraft process, and is well known in the industry. Folding carton board is a medium to heavy weight paper product made of unbleached and/or bleached pulps having basis weights from 40-350 g/m 2 .
Prior workers in this field have recognized that high-temperature treatment of linerboard can improve its wet strength. See, for example E. Back, "Wet stiffness by heat treatment of the running web", Pulp & Paper Canada, vol. 77, No. 12, pp. 97-106 (December 1976). This increase has been attributed to the development and cross-linking of naturally occurring lignins and other polymers, which phenomenon may be sufficient to preserve product wet strength even where conventional synthetic resins or other binders are entirely omitted.
It is noteworthy that wet strength improvement by heat curing has previously been thought attainable only at the price of increased brittleness (i.e., reduced folding endurance). Embrittled board is not acceptable for many applications involving subsequent deformation, and therefore heat treatment alone, to develop the wet strength of linerboard and carton board, has not gained widespread acceptance. As Dr. Back has pointed out in the article cited above, "the heat treatment conditions must be selected to balance the desirable increase in wet stiffness against the simultaneous embrittlement in dry climates." Also, in U.S. Pat. No. 3,875,680, Dr. Back has disclosed a process for heat treating already manufactured corrugated board to set previously placed resins, wherein the specific purpose is to avoid running embrittled material through a corrugator.
It is plain that improved stiffness and wet strength, on one hand, and improved folding endurance, on the other, were previously thought to be incompatible results.
Every year, the paper industry consumes millions of pounds of starch--an inexpensive natural polymer closely related to cellulose in chemical composition. Preparations of starch are added to papers and board compositions principally to improve their dry strength and their surface properties (J. P. Casey, Pulp and Paper, 3rd edition, pp. 1475-1500, 1688-1694, 1981). However, despite the well-known uses of starch, and of heat treating, separately, papers containing starch have not previously been heat treated to improve wet strength. Indeed, one of ordinary skill would not have expected heat treatment to improve starched paper, since unlike protein, starch does not cross-link when heat is applied.
We have found that heat treatment unexpectedly improves the wet strength of papers and boards containing starch. In its broadest sense, the invention comprises steps of (1) adding starch preparation into the pulp slurry or onto surface of formed paper or board; and then (2) heating the said paper or board to an internal temperature of at least 400° F. (205° C.) for a period of time sufficient to increase the wet strength of the product.
This method produces a product having folding endurance greatly exceeding that of similar product whose stiffness and wet strength have been increased by heat alone, or by starch addition alone. This is clearly shown by the results of our tests, reported below.
If starch is added to the surface of a web, it may be in its native anionic form. However, when starch is added to an aqueous slurry, we prefer to render it cationic, and therefore more soluble, by pretreating it with quaternary ammonium ion salts to give the starch chains net positive charges. Such salts do not affect the paper strength.
We prefer to raise the internal temperature of the board to at least 450° F. (232° C.) during the heat treating step, as greater stiffness and wet strength are then achieved. This may be because at higher temperatures, shorter step duration is necessary to develop bonding, and there is consequently less time for fiber degradation to occur. Also, shorter durations enable one to achieve higher production speeds.
While the invention may be practiced over a range of temperatures, pressures and duration, these factors are interrelated. For example, the use of higher temperatures requires a heat treating step of shorter duration, and vice-versa. For example, at 550° F. (289° C.), a duration of 2 seconds has been found sufficient to obtain the desired improvements, while at 420° F., considerably longer is required.
As an additional step, we prefer to rewet the product, immediately after the heat treatment, to at least 1% moisture by weight. These steps are followed by conventional drying and/or conditioning of the treated product. Of course, those skilled in the art will recognize the necessity of conditioning to a normal moisture content after treatment at high temperature. See, for example, U.S. Pat. No. 3,395,219. A certain amount of rewetting is normally done, and in fact product properties are never even tested prior to conditioning. All conventional rehumidification is done after the product has substantially cooled.
Our rewetting treatment principally differs from conditioning in that we add water, by spraying or otherwise, to a very hot and dry paper or board at the very end of the heat treatment, without intermediate cooling. It is important that water be applied to the product while it is still hot, certainly above 100° C. (212° F.), and preferably above 205° C. (400° F.). Another heat treatment or drying step may follow rewetting, on or off the machine, during a subsequent operation such as sizing, coating or calendering.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As a first step in carrying out the invention, a starch solution is added either to the paper pulp, prior to forming, or to a formed web by sizing or in any of various ways known in the art.
The water content of the web must first be reduced to at most 40% by weight and preferably to within the 10-15% range.
The heat treating and rewetting steps are then carried out, preferably on a papermaking machine, although the test data shown below was developed on a static press in a laboratory. In the heat treating step, sufficient heat is applied to the board to achieve an internal paper temperature of at least 400° F. (205° C.). The heat can be applied in the form of hot air, superheated steam, heated drying cylinders, infrared heaters, or by other means.
Alternatively, the invention may be practiced by heating paper product in an oven after a size-press. The internal temperature of the board should be brought to at least 400° F. for at least 10 seconds. Again, the nature of the heat source is not important.
Following the heat treating step, and while the paper is still hot, water is applied to it, preferably by spraying. Even though one effect of the water application is to cool the paper, it is important that the paper not be allowed to cool substantially before the water application.
The heat treated and rewetted paper is then cooled, conditioned, and calendered according to conventional procedure. The invention has been practiced as described in the following examples. The improvement in board quality will be apparent from an examination of the test results listed in the tables below.
EXAMPLE 1
A commercial bleached kraft board ("C" in the tables) was wetted to contain 10.5% moisture by weight and heat treated at 410° F. (210° C.) for 26.5 seconds ("HT"). The board was conditioned for 48 hours under standard (70° F., 65% relative moisture) conditions. Resultant board properties are listed in Table I.
TABLE I______________________________________ Heat Control Treated Board Example 1Properties (C) (HT)______________________________________Basis weight 139.5 136.3(lb/3000 ft.sup.2)Caliper (mils) 15.1 15.6Taber stiffness (gm-cm) 90/38 86/36corrected for basis weightStiffness improvement % -- -4/-5Dry Tensile lb/in 45/26.1 43.5/30.7(MD/CD)Wet Tensile, lb/in 1.6/1.1 4.5/3.2(MD/CD)Wet Strength Retention, 3.6/4.2 10.3/10.4% (MD/CD)Cracking resistance % 98/100 99/99not crackedMIT Fold, count 55/38 39/43______________________________________
EXAMPLE 2
The bleached kraft board in Example 1 was sized with corn starch (pick-up was 2.8 lb/3000 ft 2 ). One portion of the sized board was conventionally dried (110° C. for 9 seconds, "C" in the table). A second portion was heat treated at 410° F. (210° C.) for 28.8 seconds, without intermediate drying ("HT"). A third portion of the sized board was heat treated for 14.3 seconds under identical conditions, rewetted by a water spray on both sides to contain 15% moisture by weight and heat treated again for 14.3 seconds ("HT+RW"). The board was conditioned for 48 hours under standard conditions. Resultant board properties are listed in Table II. Notably, conventional drying did not improve the wet tensile of the sized board vs. the unsized one; however, both the wet tensile and stiffness of the heat-treated sized board is higher than that of the unsized board.
TABLE II______________________________________ Control Heat Twice Board Treated RewettedProperties (C) (HT) (HT + RW)______________________________________Basis weight 140.5 144.6 141.8(lb/3000 ft.sup.2)Caliper (mils) 15.8 15.9 16.0Taber stiffness 122/71 136/71 134/66(gm-cm)Stiffness improvement % -- +11/0 +10/-7Dry Tensile lb/in 68.0/43.7 70.4/41.6 70.3/43.2(MD/CD)Wet Tensile, lb/in 1.8/1.3 5.6/3.9 3.7/2.3(MD/CD)Wet Strength Retention, 2.7/3.0 8.0/9.4 5.3/5.3% (MD/CD)Cracking resistance 99/100 21/86 96/99% not crackedMIT Fold, count 64/84 10/13 21/72______________________________________
EXAMPLE 3
A mill sized (corn starch added at the mill, 2.4% pickup) bleached kraft board sample (C) was wetted to 10.9% moisture content and then treated at 410° F. (210° C.) for 15 seconds (HT). A portion of heat-treated board was rewetted and dried conventionally (HT & RW). All the samples were conditioned for 48 hours under standard conditions. Properties of these samples are given in Table III.
TABLE III______________________________________ Control Heat Board Treated RewettedProperties (C) (HT) (HT&RW)______________________________________Basis weight 153.4 154.5 155.3(lb/3000 ft.sup.2)Caliper (mils) 15.7 16.6 16.1Corrected stiffness 121/60 132/60 133/67Stiffness improvement % -- 9.1/0 9.9/11.7Dry Tensile (MD/CD) 66.1/37.4 72.9/38.1 64.2/48.5Wet Tensile, (MD/CD) 2.5/1.6 5.7/3.6 5.0/3.7Wet Strength Retention, 6.6/4.4 14.9/9.4 10.3/7.5% (MD/CD)Cracking resistance 100/100 85/7 94/58% not cracked______________________________________
EXAMPLE 4
Three unbleached kraft linerboard samples (C) were sized with different amounts of corn starch and then heat treated at 406° F. (208° C.) for 30 seconds (HT). All the samples were conditioned for 48 hours under standard conditions. Resultant linerboard properties are given in Table IV. An improvement in wet strength in observable for the starch-sized samples; the improvement increases with increases in cornstarch addition.
TABLE IV______________________________________ HEAT TREATED PLUS CORNSTARCH, CONTROL % ADD-ONProperties no HT HT 0.3 0.6 1.0______________________________________Basis weight 42.7 42.8 42.6 43.5 43.4(lb/1000 ft.sup.2)Caliper (mils) 13.1 13.4 13.7 13.8 13.6Taber Stiffness 92.5 100.5 91.7 94.5 94.5(g-cm)Dry Tensile, 105.3 87.7 89.9 93.9 97.7lb/in.Wet Tensile, 7.9 13.8 14.6 16.8 18.2lb/in.Wet Strength 7.5 15.7 15.5 17.9 18.6Retention, %MIT Fold 1702 2064 1389 1435 1740______________________________________
EXAMPLE 5
A sample of never dried kraft linerboard grade pulp having a kappa number at 110 and Canadian Standard Freeness of 750 was slurried in water and various starch preparations were added to the slurry in the amount of 1% of the oven dried pulp weight. The starches were "cooked" in water according to conventional practice to contain 8% of starch by weight. A dispersion of the pulp fibers was converted to handsheets using 12×12 inch square sheet mold. The quantity of the fibers in the dispersion was adjusted to give a sheet weight of 19 grams in the oven dry state, said weight being close to that of an air dried, 42 lb/1000 ft 2 commercial linerboard sheet. The sheets were pressed at 60 psi prior to further treatments. A control sample (C) of handsheets was dried in a conventional dryer (Emerson speed dryer, model 10) at 230° F. (110° C.). The rest of the samples were heat treated at 428° F. (220° C.) for 15 seconds (HT). All the samples were conditioned for 48 hours under standard conditions. Resultant properties are listed in Table V. One can see that wet tensile of samples containing starch is higher than that of both control and heat treated samples not containing starch.
TABLE V__________________________________________________________________________ HEAT-TREATED WITH 50:50 NOT POTATO HEAT NO STARCH: TREATED ADDI- CATIONIC CORN POTATO CAT.Properties CONTROL TIVES STARCH STARCH STARCH STARCH__________________________________________________________________________Basis weight 41.0 40.8 42.5 43.9 42.5 43.6(lb/1000 ft.sup.2)Caliper (mils) 13.4 12.8 13.3 13.8 13.1 13.9Taber Stiff- 103.3 93.0 127.5 121.0 89.0 113.0ness (gm-cm)Dry Tensile, 6.5 13.2 20.4 15.8 20.9 15.2lb/in.Wet Tensile, 0.5 2.1 4.0 2.2 4.6 2.1lb/in.Wet Strength 8.0 15.6 19.7 13.7 22.2 13.8Retention, %MIT Fold 2108 1385 1172 803 479 1225__________________________________________________________________________
Inasmuch as the invention is subject to many variations and changes in detail, the foregoing description and examples should be taken as merely illustrative of the invention defined by the following claims.
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A paper product having high stiffness, wet strength, and opacity, and good folding endurance is produced by subjecting a paper web containing a starch additive to high temperature heat treatment.
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[0001] This application claims priority under US Provisional Application 61305817 filed 18 Feb. 2010.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to displaying waveform data on pixel based display system. More particularly, the invention relates to accurately compressing waveform data and displaying the compressed data on a screen in pixel format.
[0003] In the field of test and measurement instrumentation, and specifically, modular instrument apparatus, where the captured/measured data is transferred to a main server/processor via a data bus, typical instrument apparatus may capture data using front-end analog circuitry and store it in a fast memory. Once the capture is complete, the data may be transferred to a main server/computer memory and subsequently processed for display. Transfer may take place through a data bus which can follow many different protocols. Transfer of large quantities of data may generally introduce dead-time and may thus limit the amount of data which can be placed in capture memory for subsequent processing.
[0004] When displaying waveform data, large data sets may exceed the resolution of a screen on which the waveform data will be displayed. Typical screen resolution does not exceed 2048 pixels, while waveform data may have hundreds of millions of points.
[0005] As can be seen, there is a need for a system to compress and transfer a large collection of data (e.g., a waveform) acquired from a device onto a screen without compromising any major features of the waveform.
SUMMARY OF THE INVENTION
[0006] In one aspect of the present invention, apparatus for analysis of waveform data may comprise: a data acquisition instrument for acquiring waveform data; and a data compression engine for performing calculations in-line with the data acquisition instrument to produce two-point sets from the data.
[0007] In another aspect of the present invention, a method for displaying waveform data in pixels of a display may comprise the steps of: sampling a waveform to determine data points for each sampling time; determining a time interval of a pixel on the display; selecting a number of the sampled data points during a time interval associated with a pixel of the display; assigning a first set of the selected number of the sampled data points to a first one of the time intervals; assigning a second set of the selected number of sampled data points to a second one of the time intervals; determining maximum and minimum excursions of the waveform data within the first selected time interval; determining maximum and minimum excursions of the sampled data points within the second selected time interval; determining magnitude of a last sampled data point within the first selected time interval; determining magnitude of a first sampled data point within the second selected time interval; calculating a crossover location on a y-axis as a function of a time interval associated with first pixel column; establishing a display of a first vertical line of pixels wherein the first line includes the magnitude of the minimum and maximum excursion of the first selected time interval and the crossover locations on both sides of the pixel column; and establishing a display of a second vertical line of pixels wherein the second line includes the magnitude of the minimum and maximum excursion of the second selected time interval and the crossover locations on both sides of the pixel column.
[0008] In still another aspect of the invention, a system for displaying waveform data may comprise a data acquisition instrument for determining waveform data; a waveform compression engine integral with the instrument; a data transfer bus; a display unit; and wherein the data transfer bus transfers compressed waveform data to the display unit.
[0009] 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
[0010] FIG. 1 is an exemplary waveform with various data points identified in accordance with an embodiment of the invention;
[0011] FIG. 2 is a pixel-based representation of data points of FIG. 1 in a first set of pixel columns in accordance with an embodiment of the invention;
[0012] FIG. 3 is a pixel-based representation of data points of FIG. 1 in a second set of pixel columns in accordance with an embodiment of the invention;
[0013] FIG. 4 is a diagram of a relationship between threshold levels and colors of portions of a pixel column in accordance with an embodiment of the invention;
[0014] FIG. 5 is a diagram of a relationship between digital data and colors of portions of a pixel column in accordance with an embodiment of the invention;
[0015] FIG. 6 is a block diagram of a system for displaying waveform data in accordance with an embodiment of the invention; and
[0016] FIG. 7 is a flow chart of a method for acquiring and displaying waveform data in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] 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.
[0018] Various inventive features are described below that can each be used independently of one another or in combination with other features.
[0019] Broadly, embodiments of the present invention generally provide a system in which measurement data may be captured through an analog/digital front-end. While the captured data is being stored in a fast memory, an in-line waveform compression algorithm may be running to provide a real-time result. As soon as the capture is complete, the compressed waveform data memory may be ready to be read out through a system/peripheral bus in order to be displayed.
[0020] A waveform may be a collection of digitized values (in time or amplitude) taken at a preset interval (sampling rate). In order to draw a waveform on a screen, the waveform data must be converted into x and y coordinates. The x coordinates may be calculated from the sampling rate by accumulating consecutive measurements of time for each data point, while the y coordinates are the measurement data (i.e., amplitude data) from the waveform. If there are more sampled waveform points (C) than a number (P) of pixels on the x axis of a screen, then the waveform must be compressed to fit onto the screen without losing any of its features. This may be achieved by having multiple waveform measurements share a single x coordinate location on the x axis of the screen (i.e., share a single pixel column on the screen). Multiple waveform measurements sharing an x coordinate may not have to have the same y coordinate. Variable y coordinates on a particular x coordinate may be represented as a vertical line of pixels. Since any line can be defined by two points, the vertical line of pixels formed by sharing the x coordinate can be described by minimum (Min) and maximum (Max) values in a collection of waveform data points Wi.
[0021] Typically a waveform may be measured from a trigger event. It is possible that the trigger event may fall between two sampling points. To compensate for any trigger event that falls between two sampling points, an interpolated data point between the triggering event measurement and a previous sampled measurement may be generated. Typically the interpolation may be linear, but any interpolation method may be used.
[0022] A time T, represented by each pixel on the display device, may then be computed using the equation T=(T c +T 0 )/P where T c is a total sampling acquisition time and T 0 is a time offset between the trigger event location and the first point sampled after the trigger event and P is the number of pixels on an x axis of the display. T may be a floating point number since T c +T 0 is not guaranteed to be a multiple of P. The number (G) of points that need to share a pixel can be obtained using the equation Gi=Round (Twi), where i=1 to n; where n is the display width in pixels; and where Twi is the end time of Wi and is calculated as Twi=T*i, where i=1 to n. Amplitude of waveform data at an interpolated time of the trigger event location may be added in the first set (W 1 ) that includes the trigger event to compute a Min/Max. This may also be the first crossover point for W 1 .
[0023] It should be noted that vertical lines alone do not accurately represent the captured waveform. This is because from one Min/Max vertical line to an adjacent Min/Max vertical line, there is no guarantee that the Min/Max Y ranges will overlap or represent a true crossover location. Thus, either a gap or improper connection between the adjacent Min/Max vertical lines could develop. To avoid any potential gaps or improper crossover locations, a connecting line between adjacent vertical lines representing a true crossover location in both amplitude and time axis may be required.
[0024] Referring now to FIGS. 1 , 2 and 3 , it may be seen that Min and Max points of a waveform of FIG. 1 may be represented by vertical locations of pixels as in FIG. 2 . Similarly, a value difference between Min and Max may be represented by a vertical line of pixels. Thus vertical line 14 of pixels in column 10 of FIG. 2 may represent a difference between Min and Max of the waveform in Wi of FIG. 1 . A magnitude of the line 14 of pixels may be referred to as a Min/Max pair for Wi. A Min/max-pair line of pixels 16 may also be established in column 12 for Min and Max values of the waveform in Wi+1.
[0025] It may be seen that, for example, Wi Max may be less than Wi+1 Min. Consequently, there may be a gap 18 between the two vertical lines of pixels 14 and 16 representing these values. In order to accurately represent the data we may need to include both the adjacent crossover points in the Min/Max calculations of each pixel column. To accurately define the crossover locations on the y axis from the last data point of Wi−1 and the first data point of Wi for the pixel boundary from Wi−1 to Wi, a fractional part of Twi may be factored in. This fractional part may be the time period T 0 for the first pixel column.
[0026] Because partial points cannot be displayed, rounding must take place to put the points in their closest x-axis location. As the last point in a Wi set approaches a pixel border, the first point in Wi+1 may move away from the same pixel border due to a fixed sample time. The y-axis position defining the crossover point from Wi to Wi+1 may be adjusted to reflect the resultant displaced location of the first and last points. This procedure may be repeated across the entire waveform to create a collection of vertical lines defined by two-point sets that may describe the waveform with no feature loss. Furthermore, no matter how many points are contained in Wi, only two parameters are required to fully describe one G worth of the waveform, the two parameters being minimum and maximum (Min/Max) pair for a vertical line of pixels. Thus waveform data may be compressed into these two-parameter sets. Thus the bandwidth required to display long captures may be reduced.
[0027] In cases where total number of captured points in the waveform, (C) is less than or equal to the number of pixels (P) in the display, one may use the same method to compute the crossover points spanning across multiple pixels, thus, providing a more accurate representation of the captured data.
[0028] Referring now to FIG. 4 , It may be noted that the above described two-point method can be extended to provide more detail of a waveform by highlighting possible data excursions that may be hidden between first Min/Max thresholds 50 and 52 . By adding a second set of minimum and maximum thresholds 54 and 56 for a particular W, a smaller Min/Max pair of points 58 may be generated by excluding all points that are greater than the maximum threshold 56 and all points that are less than the minimum threshold 54 . This second Min/Max pair 58 may be displayed by a vertical line 58 - 1 which may be superimposed on a line 60 that represents the Min/Max pair 50 / 52 . The line 58 - 1 may be displayed in a different color or shade from the line 60 , and may help identify acute excursions in the compressed waveform. Any number of new thresholds may be introduced to provide a higher level of detail of the waveform. Each additional threshold pair may introduce another pair of points that may be displayed.
[0029] Referring now to FIG. 5 , it may be seen that using a different color to display or reveal more details about a waveform that has been compressed to one pixel column may also be applied to digitally captured data that may only have one Min/Max value. For example a logic analyzer will have values in the waveform that are either 1 or 0. For example, a first segment 62 of a waveform may be displayed in a pixel column 62 - 1 . A second segment 64 may be displayed in pixel column 64 - 1 and so on. Different colors may be used in the pixel columns to highlight different densities of cycles or transitions within one pixel column. For every pixel column only one parameter needs to be transmitted to the display device and that is the number of transitions in a pixel column.
[0030] Referring now to FIG. 6 , an exemplary embodiment of a system 30 may employ the above described two-point compression technique. This two-point method may be implemented on an integrated waveform compression engine 32 which may function in-line with an acquisition device 34 . Simultaneously with data acquisition, an in-line waveform compression algorithm may be running in the waveform compression engine 32 to provide a real-time result. As soon as the capture is complete, the compressed waveform data memory may be ready to be read out through a system/peripheral bus in order to be displayed. The compression engine 32 may comprise an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or any other suitable programmable processing device. This may reduce the amount of data required to pass through a bus 36 to no more than two times the screen resolution of the display device 38 , thus greatly reducing the amount of processing required to display the waveform.
[0031] Referring now to FIG. 7 , a flow chart shows an exemplary embodiment of a method for displaying waveform data in pixel format.
[0032] 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 method for displaying waveform data may compress and transfer a large collection of data (e.g., a waveform) acquired from a device onto a screen without compromising any major features of the waveform. Waveform data maybe acquired with a data acquisition instrument. The acquisition instrument may perform in-line calculations to produce two-point sets from the data. The two-point sets may be transferred through an interface bus. The two-point sets may then be displayed as representations of the waveform data as vertical lines of pixels.
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FIELD OF THE INVENTION
The present invention relates to a vortex flow blower and a vane wheel therefor. Particularly, the present invention is preferable for a vane wheel with three-dimensionally curved vane surfaces.
BACKGROUND OF THE INVENTION
Japanese Unexamined Patent Applications Shou-51-57011 and Hei-2-215997 disclose a vane wheel divided into two independent parts, with the parts being subsequently joined to each other. Japanese Unexamined Patent Application Shou-51-57011, proposes a vane wheel dividing line extending perpendicularly to a rotational axis of the vane wheel. Japanese Unexamined Patent Application Hei-2-215997, proposes an arrangement wherein the vane wheel dividing line extends along edges of vanes.
SUMMARY OF THE INVENTION
An object of the present invention is provide a vane wheel which is divided into at least two members for easy production, and whose rigidity, strength and vibration-absorbing-characteristic are high.
According to the present invention, a vortex flow blower for transferring gas comprises a motor having an output rotational shaft and a vane wheel driven by the shaft. The vane wheel includes vortex flow chambers opening in a direction substantially parallel to the output rotational shaft to receive the gas therein, to urge the gas in a substantially circumferential direction of the vane wheel, and to generate and accelerate a vortex flow of gas therein. A vane member includes a hub through which the vane member is connected to the shaft. A plurality of vanes extend integrally or monolithically from the hub in a substantially radial direction of the vane wheel, with each of the vanes including a front surface for urging the gas in a substantially circumferential direction of the vane wheel, and with a vortex flow chamber wall extending integrally or monolithically from both the hub in each of the vanes. A cover means contacts and/or is pressed against the vortex flow chamber wall to form a vortex flow chamber together with the vortex flow chamber wall and the vanes.
Since the vane member includes vanes extending integrally or continuously from the hub in the substantially radial direction of the vane wheel and the vortex flow chamber wall extending integrally or continuously from both of the hub and each of the vanes, the vortex flow chamber wall rigidly supports the vanes on the hub. Therefore, although the vane wheel is divided into the vane member and the cover means, the rigidity and strength of the vanes are high. Further, since the cover means contacts with the vortex flow chamber wall, a friction between the cover means and the vortex flow chamber wall, when an adhesive adheres to the cover means and the vortex flow chamber wall so that the cover means contacts with the vortex flow chamber wall through the adhesive, a deformation of the adhesive therebetween, absorbs a vibration of the vane wheel, particularly a vibration generated in the vortex flow chambers. A pressing force between the cover means and the vortex flow chamber wall is increased so as to absorb the vibration. Therefore, although the vane wheel is divided into the vane member and the cover means, the vane wheel is prevented from generating the vibration.
The vortex flow chamber wall may curve to project in the substantially radial and/or circumferential direction of the vane wheel so that a section modulus and a geometrical moment of inertia of an integral or continuous combination of the vortex flow chamber wall and the vanes are remarkably increased, and a contact area between the cover means and the vortex flow chamber wall is increased. Therefore, the rigidity, strength and vibration-absorbing-characteristic are further improved.
It is preferable for each of the vanes to be prevented from being divided. Each of the front surfaces may form an inclined angle relative to an imaginary plane substantially perpendicular to the output rotational shaft, and the angle is less than a right angle. In this case, a casting mold for forming the inclined vanes can be inserted and easily securely supported through a below mentioned through-holes or notches so that the vane wheel with three-dimensionally curved vane surfaces can be correctly formed. The vortex flow chamber wall may have a through-hole therein, and the cover means may cover the through-hole. The cover means may extend into the through-hole. The vane member may include a through-hole therein, and further include a radially inner vortex flow chamber wall portion and a radially outer vortex flow chamber wall portion divided by the through-hole from the vortex flow chamber wall. The vane member may include notches each extending radially inwardly from an outside of the vane member between the vanes adjacent to each other, and the cover means may cover the notches. The cover means may extend into the notches. The through-holes or notches are preferable for increasing a volume on the vortex flow chambers. When cover means extends into the notches or through-holes, an abrupt change of an inner surface of the vortex flow chambers at the notches or through-holes is prevented.
A reverse surface of the vortex flow chamber wall and, if necessary a reverse surface of the hub may form a substantially flat surface plane, and the cover may comprise a substantially flat surface for contacting with the substantially flat surface plane to form the vortex flow chambers together with the vanes and the vortex flow chamber wall as shown in FIGS. 28-30. The cover may further comprise projections on the substantially flat surface so that the projections extend into or fill the notches or through-holes of the vane member to form a smooth inner surface shape of the vortex flow chambers.
The vortex flow chamber wall may have a portion extending in the substantially radial direction of the vane wheel and connecting the vanes adjacent to each other in the substantially circumferential direction of the vane wheel so that the rigidity and strength of the vanes adjacent to each other in the substantially circumferential direction of the vane wheel are improved. The vanes may be prevented from extending over or below the vortex flow chamber wall as seen in the direction substantially parallel to the shaft, so that the casting mold for forming the vane member can be easily and securely supported easily and securely.
The cover means may have dents receiving the vanes so that the vanes are rigidly supported by the cover means in a substantially circumferential direction of the vane wheel. The vortex flow blower may further comprises a metal member joined with the vane member and with the cover means so that the cover means is connected to the vane member. The vortex flow blower may further comprises a first metal member joined with the vane member and a second metal member joined with the cover means so that the cover means is connected to the vane member, and an angle between a longitudinal axis of the first metal member and an imaginary plane substantially perpendicular to the output rotational shaft may be different from another angle between a longitudinal axis of the second metal member and the imaginary plane. The cover means may be connected to the shaft independently of the vane member. The cover means and the vane member may have respective surfaces extending substantially parallel to each other to engage with each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a vortex flow blower according to the present invention.
FIG. 2 is a front view of a vane member according to the present invention.
FIG. 3 is a cross-sectional view taken along a line III--III in FIG. 2.
FIG. 4 is a partially cross-sectional schematic view of a vane member according to the present invention.
FIG. 5 is a front view of a cover according to the present invention.
FIG. 6 is a cross-sectional side view showing the cover of FIG. 5.
FIG. 7 is a cross-sectional side view of a combination of upper and lower cast molds for forming vanes, vortex flow chambers and a hub according to the present invention.
FIG. 8 is a reverse view of a vane member according to the present invention.
FIG. 9 is a cross-sectional view similar to FIG. 3 of another cover according to the present invention.
FIG. 10 is a cross-sectional similar to FIG. 3 of another cover according to the present invention.
FIG. 11 is a cross-sectional view similar to FIG. 3 of another cover according to the present invention.
FIG. 12 is a cross-sectional view similar to FIG. 3 of another cover according to the present invention.
FIG. 13 is a cross-sectional view of a connection between a vane member and a cover according to the present invention.
FIG. 14 is a cross-sectional view of another connection between a vane member and a cover according to the present invention.
FIG. 15 is a cross-sectional view of another connection between a vane member and a cover according to the present invention.
FIG. 16 is a cross-sectional view of another connection between a vane member and a cover according to the present invention.
FIG. 17 is a cross-sectional view of another cover according to the present invention.
FIG. 18a is a front view of another vane member according to the present invention.
FIG. 18b is a front view of another cover according to the present invention.
FIG. 18c is a cross-sectional view of the vane member of FIG. 18a.
FIG. 18d is a cross-sectional view of the cover of FIG. 18b.
FIG. 19a is a cross-sectional view of an engagement between a vane member and a cover according to the present invention.
FIG. 19b is a cross-sectional view of another engagement between a vane member and a cover according to the present invention.
FIG. 20 is a cross-sectional view of another connection between a vane member and a cover according to the present invention.
FIG. 21a is a cross-sectional view of another connection between a vane member and a cover according to the present invention.
FIG. 21b is a partial side view of the another connection of FIG. 21a.
FIG. 22a is a front view of another vane member according to the present invention.
FIG. 22b is a front view of another cover according to the present invention.
FIG. 22c is a cross-sectional view of the another vane member of FIG. 22a.
FIG. 22d is a cross-sectional view of the another cover of FIG. 22b.
FIG. 23a is a cross-sectional view of another connection between a vane member and a cover around a driving shaft according to the present invention.
FIG. 23b is a side view of engaging projections of a vane member according to the present invention.
FIG. 23c is a side view of engaging dents of a cover according to the present invention.
FIG. 23d is a side view of an engagement between the projections and dents shown in FIGS. 23b and 23c.
FIG. 24a is a partially cross-sectional schematic view of another vane member with a curved vortex flow chamber wall extending radially inwardly and outwardly and with through-holes terminating at vanes to divide the vortex flow chamber wall into radially inner and outer portions, according to the present invention.
FIG. 24(b) is a top view of a vane member in accordance with FIG. 24(a);
FIG. 24(c) is a side view of FIG. 24(b); and
FIG. 24(d) is a sectional view along section line (d)--(d) of FIG. 24(b).
FIG. 25 is a partial cross-sectional schematic view of another vane member with a curved vortex flow chamber wall extending radially inwardly and with through-holes in the vortex flow chamber wall, according to the present invention.
FIG. 26 is a partial cross-sectional schematic view of another vane member with a curved vortex flow chamber wall extending radially outwardly and with through-holes in the vortex flow chamber wall, according to the present invention.
FIG. 27 is a partial cross-sectional schematic view showing another vane member with a curved vortex flow chamber wall extending radially outwardly and with notches extending inwardly from an outside of the vane member.
FIG. 28 is a partial cross-sectional schematic view showing another vane member.
FIGS. 29 and 30 are front and side-cross-sectional views of cover for the another vane member of FIG. 28.
DETAILED DESCRIPTION
As shown in FIGS. 1-4 and 8, a vortex flow blower has a vane wheel 1, an electric motor 4 for driving the vane wheel 1, a casing 2 with a pressure increasing passage 3 extending substantially around a rotational shaft axis 7 of the motor 4 and the vane wheel 1 and opening in a direction parallel to the rotational shaft axis 7, an inlet 5 opening at an end of the pressure rising passage 3 to take in air, an outlet (not shown) opening at another end of the pressure increasing passage 3 to discharge the air, and a partition wall 6 arranged between the end and another end of the pressure rising passage 3.
The vane wheel 1 is mounted on an output rotational shaft 4s of the motor 4, and includes a hub 8 connected to the output rotational shaft 4s, a vortex flow chamber wall 10 for forming vortex flow chambers 9 opening to and along the annular pressure increasing passage 3 in a direction parallel to the rotational shaft axis 7 and partitioned by a plurality of vanes 12 extending substantially radially, and a cover 11 for covering through-holes or notches 50 of the vane wheel 1 at an opposite side of the casing 2. The hub 8, the vanes 12 and the vortex flow chamber wall 10 forming the vane member are made integrally of a light alloy, for example, aluminum, aluminum alloy or the like through a mold process, for example, a die cast molding process.
The vanes 12 project forward in a vane wheel rotational direction to be inclined relative to an imaginary plane perpendicular to the axis 7 so that the air received by the vanes from the inlet 5 is urged strongly toward a wedge-shaped space or bottom of the vane wheel 1 formed by the vanes 12 and the wall 10 and cover 11. The air is accelerated by the vanes 12 in a circumferential direction of the vane wheel 1, and a vortex flow of the air is generated and accelerated in the vortex flow chambers 9. The vortex flow of the air proceeds in the circumferential direction of the vane wheel 1 along an annular passage formed by the pressure increasing passage 3 and the vortex flow chambers 9. Thereafter, the air pressurized by being accelerated in the circumferential direction of the vane wheel 1 and in a spiral direction of the vortex flow, is discharged from the outlet.
The wall 10 forms the through-holes 50 at the opposite side of the casing 2, and the vanes 12 extend over or below the through-holes 50 as viewed in a direction parallel to the axis 7.
The cover 11 has an inner surface fitting onto a reverse surface of the wall 10 as shown in FIGS. 5 and 6, so that the vane wheel 1 is formed by the cover 11 and an integral or monolithic combination as the claimed vane member of the hub 8, the vanes 12 and the vortex flow chamber wall 10. The cover 11 contacts with the wall 10, preferably with a compression force there-between. The cover 11 may be divided into a plurality of members each of which contacts with and fits onto the reverse surface of the wall 10, preferably with the compression force therebetween. The cover 11 may be made of steel, aluminum, aluminum alloy or the like, through a press or molding process.
As shown in FIG. 7, when an upper mold 200 and monolithically a lower mold 300 are combined with each other to integrally or form integrally the hub 8, the vanes 12 and the vortex flow chamber wall 10, the lower mold 300 for forming the reverse surface of the wall 10 and vanes 12 can extend into an inside of the vane wheel 1 through the through-holes or notches 50, and the combination of the upper mold 200 and lower mold 300 can be disassembled in directions indicated by the arrows a and b.
As shown in FIG. 9, the cover 11 may have projections 11a which extend into the through-holes or notches 50 respectively, and whose upper surfaces form respective parts of semicircle inner surfaces of the vortex flow chambers 9 to prevent an abrupt change of the inner surfaces of the vortex flow chambers 9 at the through-holes or notches 50, so that a smooth air flow is performed in the vortex flow chambers 9.
As shown in FIG. 10, the vortex flow chamber wall 10 may be tapered to prevent the abrupt change of the inner surfaces of the vortex flow chambers 9 at boundaries between an edge of the wall 10 and the through-holes or notches 50, so that the smooth air flow is performed in the vortex flow chambers 9. As shown in FIG. 11, the vortex flow chamber wall 10 may have projections 13 and the cover 11 may have holes 11h so that the cover 11 is pressed against and fixed to the wall 10 to form the vane wheel 1 after forward ends of the projections 13 are plastically deformed or caulked. As shown in FIG. 12, the projections 13 may be arranged on the vanes 12. As shown in FIG. 13, it is not necessary for combinations of the projections 13 and the holes 11h to be arranged at every vortex flow chambers 9. As shown in FIG. 14, the projections 13 may be arranged on the hub 8. As shown in FIG. 15, the cover 11 may be pressed against and fixed to the integral combination of the hub 8, the vanes 12 and the vortex flow chamber wall 10 by bolts 17 extending through bolt apertures 15 and bolt accomodating holes 16. In this embodiment, the hub 8 is connected to the shaft 4s through a boss 8b included in the cover 11. As shown in FIG. 16, the integral combination of the hub 8, the vanes 12 and the vortex flow chamber wall 10 may be connected to the shaft 4s through the hub 8, and the cover 11 may be directly connected to the shaft 4s.
As shown in FIG. 17, the vortex flow chamber wall 10 and the cover 11 may have wedge-shaped taper projections and dents engage tightly with each other so that a hermetical seal is formed therebetween to prevent water from penetrating therebetween. It is preferable for the integral assembly of the hub 8, the vanes 12 and the vortex flow chamber wall 10 and the cover to be made of a common material to prevent a contact corrosion between different materials. If a material of the integral assembly and a material of the cover 11 are different from each other, it is preferable that an electric potential difference between the materials is small and an electrically insulating varnish of, for example, polyester type or epoxy type is arranged between the integral assembly and the cover 11. The integral or monolithic combination of the hub 8, the vanes 12 and the vortex flow chamber wall 10 may contact the cover 11 through an adhesive therebetween for fixing the cover 11 to the monolithic combination.
As shown in FIGS. 18a-18d, the vane wheel 1 may be composed of an integral or monolithic combination 109 as the vane member of a boss 109a, a hub 109b, vanes 108 and an outer limb 109c, and an integral or monolithic combination 110 as the cover means of an inner cylindrical portion 110a, a vortex flow groove wall 107 forming an annular vortex flow groove 17 and an outer cylindrical portion 110b. As shown in FIGS. 19a and 19b, the vanes 108 are fitted into the annular vortex flow groove 17 so that the annular vortex flow groove 17 is divided by the vanes 108 to form the vortex flow chambers 9. Each of the vanes 108 has at least one projection 111 fitted into at least one dent or radially extending groove 112 formed on the annular vortex flow groove 17 so that the vanes 108 is rigidly and strongly supported in the circumferential direction of the vane wheel 1 against an air pressure. The integral combinations 109 and 110 are fixedly joined with a cast portion 113 which is formed by utilizing the integral combinations 109 and 110 as a mold core.
As shown in FIGS. 21a and 21b, the integral combinations 109 and 110 are fixedly joined with casted portions 114 which are formed by inserting a melted metal into aligned grooves in the combinations 109 and 110. Preferably for strong fixing an inclined direction of angle θ of the cast portions 114 at a radially outer side of the vane wheel 1 is reverse to that of the cast portions 114 at a radially inner side thereof.
As shown in FIGS. 22a-23d, the vane wheel 1 may be composed of an integral or monolithic combination 115 as the vane member of a hub 115a mounted on the shaft 4s, the vanes 108 and an outer limb 115c, and an integral or monolithic combination 116 with the cover means of a boss 116a mounted on the shaft 4s, inner ribs 116b, the vortex flow groove wall 107 and an outer cylindrical portion 116c. The hub 115a may be fitted into the boss 116a around the shaft 4s. The outer limb 115c and the outer cylindrical portion 116c may have projections 118 and dents 119 engaged with each other by rotating the limb 115c relative to the cylindrical portion 116c as shown by an arrow R. This structure is appropriate when the monolithic combinations 115 and 116 to be fixed to each other are made of a plastic resin.
As shown in FIGS. 24-26, the vortex flow chamber wall 10 curved to extend radially and forming the through-holes or notches 50 may have a radially inner extension length different from a radially outer extension length. FIGS. 24(a)-(d) illustrate another vane member in accordance with the invention with FIG. 24(a) being a partial sectional view, FIG. 24(b) being a top view, FIG. 24(c) being a side view and FIG. 24(d) being a sectional view of FIG. 24(b) along section line d--d. The cover 11 is spaced from the flow chamber wall 10. The through-holes or notches 50 may be surrounded by the wall 10, or alternatively may terminate at the vanes 12. As shown in FIG. 27, the notches 50 may extend radially inwardly from an outside of the vane wheel 1 to the vortex flow chamber wall 10.
As shown in FIG. 28, the wall 10 may have an annular planar reverse surface. The annular planar reverse surface is covered by the cover 11, which includes a planar surface for contacting with the annular planar reverse surface as shown in FIGS. 29 and 30. The cover 11 may have projections 51 extending into or filling the through-holes 50 to form a smooth inner surface of the vortex flow chambers together with the vanes 12 and the vortex flow chamber wall 10.
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A vane wheel driven by a shaft for transferring a gas, comprises, vortex flow chambers opening in a direction substantially parallel to the shaft to receive the gas, to urge the gas in a substantially circumferential direction of the vane wheel, and to generate and accelerate a vortex flow of the gas. A vane member includes a hub through which the vane member is connected to the shaft, with the vane member including a plurality of vanes each extending integrally from the hub in a substantially radial direction of the vane wheel. Each of the vanes includes a front surface for urging the gas in the substantially circumferential direction of the vane wheel. A vortex flow chamber wall extends integrally from both the hub and each of the vanes, and a cover contacts the vortex flow chamber wall to form the vortex flow chambers together with the vortex flow chamber wall and the vanes.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application No. 61/412,612 entitled “Amino Terminated Phosphonamide Oligomers and Flame Retardant Compositions Therefrom” filed Nov. 11, 2010, which is herein incorporated by reference in its entirety.
GOVERNMENT RIGHTS
This invention was developed with Government support under Contract No. FA8650-07-C-5907 awarded by the Department of the Air Force. The Government has certain rights in the invention.
PARTIES TO A JOINT RESEARCH AGREEMENT
Not applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not applicable.
BACKGROUND
The phosphorus content of polymer compositions is important to achieving flame retardancy. High molecular weight polyphosphonamides often have poor solubility or miscibility in the host polymer, and due to their high melt viscosity, significantly detract from the melt processability of the host resin. When added to thermosetting polymers, a reduction in glass transition temperature (Tg), heat distortion temperature (HDT), and modulus often results. Additionally, adding high molecular weight polyphosphonamides to other polymers leads to a lower phosphorus content compared to using oligomers.
Amino terminated phosphonamide oligomers can react with a variety of monomers and oligomeric species to form copolymers. For example, they can be co-reacted with epoxy formulations to produce a flame retardant polymer in which the phosphonamide oligomer is chemically incorporated into the matrix via covalent bond formation. Likewise, the amino terminated phosphonamide oligomers can be used as reactants to form copolyamides, copolyureas, copolyimides and any other copolymers that can react with an amine functional group. Therefore, there is a need for phosphonamides prepared by any synthetic route that have reactive amino end groups at sufficient concentration to participate in bond forming reactions with other monomers or reactive species to form copolymers.
SUMMARY OF THE INVENTION
Embodiments described herein include a composition comprising an amino terminated phosphonamide of general Formula I:
where R is a C 1 to C 20 alkyl or, optionally substituted, aryl group, X is an aromatic or aliphatic group, Z is:
and
n is an integer of from 1 to about 20. In some embodiments, n can be an integer of from 1 to about 10. In other embodiments, the amino-terminated phosphonamide may include at least about 50% amine end-groups based on the total number of end groups. In certain embodiments, R may be methyl, and in some embodiments, each —NH—X—NH— can be derived from a diamine, a triamine, or a polyamine.
Other embodiment are directed to compositions including an amino terminated phosphonamide of general Formula II:
where each of R 1-5 is individually a C 1 to C 20 alkyl or, optionally substituted, aryl group, each of X 1-4 is individually, an aromatic, cycloalkyl, or aliphatic group, n and m are each individually an integer of from 0 to about 20 and each Z is, independently:
In some embodiments, each m and n are each individually integers from 0 to about 10. In other embodiments, the amino-terminated phosphonamide includes at least about 50% amine end-groups based on the total number of end groups. In particular embodiments, each of R 1-5 can be methyl, and in other embodiments, each of —NH—X 1-4 —NH— can independently derived from a diamine, a triamine, or a polyamine.
Further are directed to compositions that include the amino terminated phosphonamide of the invention including those of Formulae I and II and one or more polycarbonates, epoxy derived polymers, polyepoxies, benzoxazines, polyacrylates, polyacrylonitriles, polyesters, poly(ethylene terephthalate)s, poly(trimethylene terephthalate) and poly(butylene terephthalate)s, polystyrenes, polyureas, polyurethanes, polyphosphonates, poly(acrylonitrile butadiene styrene)s, polyimides, polyarylates, poly(arylene ether)s, polyethylenes, polypropylenes, polyphenylene sulfides, poly(vinyl ester)s, polyvinyl chlorides, bismaleimide polymers, polyanhydrides, liquid crystalline polymers, cellulose polymers, and combinations thereof, and in some embodiments, these compositions may further include one or more fillers, fibers, surfactants, organic binders, polymeric binders, crosslinking agents, coupling agents, additional flame retardants, anti-dripping agents, anti-static agents, catalysts, colorants, inks, dyes, antioxidants, stabilizers, or combinations thereof.
Still further embodiments are directed to methods for preparing the oligomeric amino terminated phosphonamides of the invention including those of general Formulae I and II, and methods for preparing compositions including the oligomeric amino terminated phosphonamides and another thermoplastic or thermoset resin. Additional embodiments including articles of manufacture and various coatings and moldings created from the oligomeric amino terminated phosphonamides of the invention and compositions including these oligomeric amino terminated phosphonamides.
DESCRIPTION OF DRAWINGS
Not applicable.
DETAILED DESCRIPTION
Before the present compositions and methods are described, it is to be understood that this invention is not limited to the particular processes, compositions, or methodologies described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present invention, which will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, devices, and materials are now described. All publications mentioned herein are incorporated by reference in their entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.
It must also be noted that, as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a combustion chamber” is a reference to “one or more combustion chambers” and equivalents thereof known to those skilled in the art, and so forth.
As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45%-55%.
The terms “flame retardant,” “flame resistant,” “fire resistant,” or “fire resistance,” as used herein, means that the composition exhibits a limiting oxygen index (LOI) of at least 27. “Flame retardant,” “flame resistant,” “fire resistant,” or “fire resistance,” may also refer to the flame reference standard ASTM D6413-99 for textile compositions, flame persistent test NF P 92-504, and similar standards for flame resistant fibers and textiles. Fire resistance may also be tested by measuring the after-burning time in accordance with the UL test (Subject 94). In this test, the tested materials are given classifications of UL-94 V-0, UL-94 V-1 and UL-94 V-2 on the basis of the results obtained with the ten test specimens. Briefly, the criteria for each of these UL-94-V-classifications are as follows:
UL-94 V-0 the average burning and/or glowing time after removal of the ignition flame should not exceed 5 seconds and none of the test specimens should release and drips which ignite absorbent cotton wool.
UL-94 V-1: the average burning and/or glowing time after removal of the ignition flame should not exceed 25 seconds and none of the test specimens should release any drips which ignite absorbent cotton wool.
UL-94 V-2: the average burning and/or glowing time after removal of the ignition flame should not exceed 25 seconds and the test specimens release flaming particles, which ignite absorbent cotton wool.
Fire resistance may also be tested by measuring after-burning time. These test methods provide a laboratory test procedure for measuring and comparing the surface flammability of materials when exposed to a prescribed level of radiant heat energy to measure the surface flammability of materials when exposed to fire. The test is conducted using small specimens that are representative, to the extent possible, of the material or assembly being evaluated. The rate at which flames travel along surfaces depends upon the physical and thermal properties of the material, product or assembly under test, the specimen mounting method and orientation, the type and level of fire or heat exposure, the availability of air, and properties of the surrounding enclosure. If different test conditions are substituted or the end-use conditions are changed, it may not always be possible by or from this test to predict changes in the fire-test-response characteristics measured. Therefore, the results are valid only for the fire test exposure conditions described in this procedure. The state-of-the-art approach to rendering polymers flame retardant is to use additives such as brominated compounds or compounds containing aluminum and/or phosphorus. Use of these additives can have a deleterious effect on the processing characteristics and/or the mechanical performance of products produced from them. In addition, some of these compounds are toxic, and can leach into the environment over time making their use less desirable. In some countries certain brominated additives and aluminum and/or phosphorus containing additives are being phased-out of use because of environmental concerns.
Embodiments of the invention are generally directed to amino-terminated phosphonamides, and in some embodiments oligomeric amino terminated phosphonamides. Other embodiments are directed to methods for producing amino terminated phosphonamides. Further embodiments are directed to methods for using amino terminated phosphonamides in thermoset resins, and certain embodiments are directed to thermoplastics having amino terminated phosphonamides and oligomeric amino terminated phosphonamides incorporated into the polymer matrix. Still further embodiments are directed to articles of manufacture that include these thermoplastics having amino terminated phosphonamides and oligomeric amino terminated phosphonamides incorporated into the polymer matrix.
Embodiments are not limited to particular phosphonamides. Various known phosphonamides can be reformulated to include amino termini and are encompassed by the invention. In particular embodiments, the amino terminated phosphonamides of the invention may have the structure of general Formula I:
where R is a C 1 to C 20 alkyl or, optionally substituted aryl group, X is an aromatic, cycloalkylene, or aliphatic group, n is an integer of from 1 to about 20, and Z is:
In other embodiments, the predominately amino terminated phosphonamide oligomers may include compounds of Formula II:
where R 1-5 are each individually a C 1 to C 20 alkyl or, optionally substituted, aryl group, X 1-4 are each individually, an aromatic, cycloalkylene, or aliphatic group, n and m are an integer of from 0 to about 20, and each Z is, independently:
In some embodiments, m and n may each independently be from about 0 to about 10. In other embodiments, m may be an integer of from 0 to about 4, such that the branching, or potential branching, and n may be any integer from 1 to about 10.
In particular embodiments, each —NH—X—NH— provided in Formulae I and II, including the amine containing moieties including X1-4, may be derived from an amine containing monomer including all known diamine, triamine, or polyamine containing monomer. In certain embodiments, each —NH—X—NH— may be derived from the same amine containing monomer, and in other embodiments, each —NH—X—NH— may be derived from two or more different amine containing monomers. Exemplary amine containing monomers include alkanediamines, alkanetriamines, arylamines, cycloalkylamines, or any combinations thereof, and in various embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 12 or about 20 carbon atoms. In particular embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 8 carbon atoms. More specific non-limiting examples of suitable diamines, triamines, and polyamines include m-xylylenediamine, di(4-aminophenyl)methane, di(4-aminocyclohexyl)methane, 2,2-di(4-aminophenyl)propane, 1,4-diaminobutane, 1,3-bis(aminomethyl)-cyclohexane, 1,4-bis(aminomethyl)-cyclohexane, 2,5-bis(aminomethyl)-bicyclo-[2,2,1]heptane and/or 2,6-bis-(aminomethyl)-bicyclo[2,2,1]heptane, bis-(4-aminocyclohexyl)-derivative of an alkane having from 1 to 6 carbon atoms, and p-xylylene-diamine 2,2-di(4-aminocyclohexyl)propane, and triamine derivatives of these diamines, any mixtures, or combinations thereof. In certain embodiments, —NH—X—NH— may be derived from polyether amine or JEFFAMINE, which are described herein below.
The weight average molecular weight (Mw) of these predominately amino terminated phosphonamide oligomers can vary based on the number of monomers incorporated into the polymer chain and can be form about 200 g/mole to about 10,000 g/mole or about 500 g/mole to about 7,500 g/mole in embodiments (all expressed against polystyrene (PS) standards). The term “predominately” as used herein is meant to infer that at least 50% of the available end groups include an amine group, and in some embodiments, predominately may refer to phosphonamides having from about 50% to about 100%, about 60% to about 90%, about 60% to about 80%, or any range between these exemplary ranges of amine end groups based on the total number of available end groups.
The predominately amino terminated phosphonamide oligomers of such embodiments may be prepared by combining an amine containing monomer and a phosphonate containing monomer and heating this mixture under vacuum. In some embodiments, the reaction mixture may further include a polymerization catalyst such as, for example, magnesium chloride. In general, the vacuum may be sufficient to remove volatile components, such as phenol, produced as the phosphonamide oligomer is made. In some embodiments, the vacuum may be applied in a step wise manner, in which the vacuum is increased and the pressure of the reaction is reduced one or more times, during the polymerization process, and in other embodiments, the pressure may be gradually reduced throughout the polymerization. In still other embodiments, the vacuum may be increased and the pressure reduced both step wise and gradually in the same polymerization method. For example, in some embodiments, the vacuum may be applied to produce an initial pressure of from about 250 mmHg to about 50 mmHg and the pressure may be reduced gradually, in a step wise manner, or both to from about 10 mmHg to about 5 mmHg. In other exemplary embodiments, the initial pressure may be from about 250 mmHg to about 150 mmHg, and this pressure may be reduced to from about 40 mmHg to about 80 mmHg and then reduced again to about 20 mmHg to about 5 mmHg to produce a method with 3 vacuum steps. Other methods may include more than 3 steps, and still other methods may include less than 3 steps, for example, pressure may be gradually reduced throughout polymerization from about 250 mmHg or 150 mmHg to about 10 mmHg or about 5 mmHg.
The temperature of the reaction may be maintained at any temperature at which polymerization may occur. For example, in some embodiments, the reaction temperature may be from about 175° C. to about 300° C., and in other embodiments, the reaction temperature may be from about 200° C. to about 250° C. or 275° C. In some embodiments, a constant reaction temperature may be maintained throughout the polymerization, and in other embodiments, the reaction temperature may change at various times throughout the polymerization reaction. In particular embodiments, the reaction temperature may be increased at steps as the pressure is decreased. For example, in the context of the exemplary embodiments above, the initial reaction temperature may be about 175° C. to about 220° C. when the pressure is from about 250 mmHg to about 150 mmHg. The reaction temperature may be increase to from about 200° C. to about 230° C. when the pressure reduced to from about 40 mmHg to about 80 mmHg, and the reaction temperature may be increased to from about 220° C. to about 275° C. when the pressure is reduced to about 20 mmHg to about 5 mmHg.
The reaction time may be any amount of time necessary to provide sufficient polymerization and may vary with reactants, catalysts, reaction temperatures and pressures, and so on. The skilled artisan may vary the reaction time according to such considerations. In general, the total reaction time may be from about 10 hours to about 40 hours, and in some embodiments, the total reaction time may be from about 15 hours to about 25 hours. The reaction time for various steps or temperature and pressure intervals may also vary, and each step or interval may individually be from about 2 hours to about 20 hours. In certain embodiments, a lower temperature, higher pressure first step or interval may be from about 2 hours to about 6 hours in length, followed by a longer 10 hour to 25 hour step or interval where the temperature is increased and the pressure is reduced. As discussed above, the reaction time for each step or interval may vary and can be determined by the skilled artisan.
In some embodiments, the amine containing monomer may be provided in a molar excess to increase the number of amine end-groups on the phosphonamide oligomers. As discussed above the amine containing monomer may be any diamine, triamine, or polyamine known in the art. In particular embodiments, the amine containing monomer may be provided in a molar excess of at least 10%, and in other embodiments, the amine containing monomer may be provided in a molar excess of from about 10% to about 50%, about 10% to about 30%, or about 10% to about 25%. Without wishing to be bound by theory, when an amine containing monomer is combined with a phosphodiester containing monomer and is provided in a molar excess of 10%, the resulting oligomeric phosphonamide may have about 5% excess amino end-groups versus phosphonate-ester end groups. In still other embodiments, the reaction mixture may include a branching agent, and the ratio of amine to phosphodiester containing monomers may be adjusted to ensure excess amine end-groups in the resulting oligomeric phosphonamide.
In further embodiments, the amino terminated phosphonamides described above can be prepared by reacting diamines, triamines, polyamines, or combinations thereof with phosphinic dihalides.
In various embodiments, amine containing monomer may be any known diamine, triamine, or polyamine containing monomer. Exemplary amine containing monomers include alkanediamines, alkanetriamines, arylamines, cycloalkylamines, or any combinations thereof, and in various embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 12 or about 20 carbon atoms. In particular embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 8 carbon atoms. More specific non-limiting examples of suitable diamines, triamines, and polyamines include m-xylylenediamine, di(4-aminophenyl)methane, di(4-aminocyclohexyl)methane, 2,2-di(4-aminophenyl)propane, 1,4-diaminobutane, 1,3-bis-(aminomethyl)-cyclohexane, 1,4-bis(aminomethyl)-cyclohexane, 2,5-bis(aminomethyl)-bicyclo-[2,2,1]heptane and/or 2,6-bis-(aminomethyl)-bicyclo[2,2,1]heptane, bis-(4-aminocyclohexyl)-derivative of an alkane having from 1 to 6 carbon atoms, and p-xylylene-diamine 2,2-di(4-aminocyclohexyl)propane, and triamine derivatives of these diamines, any mixtures, or combinations thereof.
In particular embodiments, the amine containing monomer may be polyether amines such as JEFFAMINEs. JEFFAMINEs are well known in the art and any polyether amine or JEFFAMINE can be used to prepare the phosphonamide oligomers of the invention. In particular embodiments, the amine containing monomer may be a JEFFAMINE of the structures provided below.
Name
Structure
x
Ave Mw
D230 D2000
~2.5 ~33
230 2000
T403
n = 1 (x + y + z) = 5 − 6 R = CH 2 CH 3
440
In certain embodiments, the phosphonate containing monomer may be a diaryl alkyl- or arylphosphonates or optionally substituted diaryl alkyl- or arylphosphonates of embodiments may be of general formula (I):
where R 2 may be C 1 -C 20 alkyl or, optionally substituted, aryl and R 1 may be an aryl group, or a substituted aryl group of formula (II):
where R 3 , R 4 , R 5 , R 6 , and R 7 may independently be any substituent including but not limited to hydrogen, C 1 -C 20 alkyl, aromatic or aryl group, trifluoromethyl, nitro, cyano, halide (F, Cl, Br, I), C 1 -C 20 alkyl ether, C 1 -C 20 alkyl ester, benzyl halide, benzyl ether, aromatic or aryl ether, or optionally substituted versions of these, and R 3 , R 4 , R 5 , R 6 , and R 7 are essentially unaffected by the reaction. In certain embodiments, the diaryl alkylphosphonate may be diphenyl methylphosphonate.
The amino terminated phosphonamides and oligomeric amino terminated phosphonamides described above may include at least one amino termini, and in certain embodiments, the amino terminated phosphonamides and oligomeric amino terminated phosphonamides may have two or more amino termini. In some embodiments, the molecular weight of the oligomeric amino terminated phosphonamides may be substantially the same. In other embodiments, the oligomeric amino terminated phosphonamides may be present in a statistical mixture of various molecular weight species. In such statistical mixtures, an amino group is present of both ends of the same molecule, one end of the molecule, or on neither end of different molecules.
The oligomeric amino-terminated phosphonamides described herein overcome the problems of toxicity and leaching while satisfying the UL or comparable standardized flame resistance rating performance requirements without detracting from important physical, mechanical and processing properties. This is achieved by formulating a composition of a reactive monomer, oligomer or polymer and an effective amount of an amino terminated phosphonamide oligomer. The amount of the amino terminated phosphonamide may be provided in any appropriate flame retarding amount and can range up to about 50% by weight of the final composition, and in some embodiments, the amount of amino terminated phosphonamide may be from about 10% to about 30%, by weight of the final composition. In some embodiments, the oligomeric amino-terminated phosphonamide can be cured with the host resin, and in other embodiments, the oligomeric amino terminated can be pre-reacted with the host resin.
The amino terminated phosphonamide oligomers of various embodiments can be combined with a variety of other monomers, oligomers, and polymers including, for example, epoxies, ureas, esters, urethanes, and imides. In certain embodiments, the amino terminated phosphonamides and oligomeric amino terminated phosphonamide oligomers may be incorporated into thermoplastic and thermosetting polymers such as, but not limited to, polyester, polycarbonate, polyacrylate, polyacrylonitrile, polystyrene (including high impact strength polystyrene and syndiotactic polystyrene), polyurea, polyurethane, linear and branched polyphosphonates, poly(acrylonitrile butadiene styrene), polyimide, polyarylate, poly(arylene ether), polyethylene, polypropylene, polyphenylene sulfide, poly(vinyl ester), polyvinyl chloride, bismaleimide polymer, polyanhydride, liquid crystalline polymer, epoxies and polyepoxies, such as polymers resulting from the reaction of one or more epoxy monomers or oligomers with one or more chain extenders or curing agents such as a mono or multifunctional phenol, amine, benzoxazine, anhydride or combination thereof, benzoxazine, polyphosphate, cellulose polymer, or any combination thereof. These exemplary thermoplastics and thermosets are well known commercially available commodity engineering plastics that used in a variety of applications. Embodiments of the invention encompass any other such engineering plastics not specifically included in the above lists, and combinations of various thermoplastics and thermoset resins.
In some embodiments, the compositions including a thermoplastic or thermoset resin and an amino-terminated phosphonamide or an oligomeric amino-terminated phosphonamide may further include other additives such as, for example, one or more curing agents, additional flame retardant additives, fillers, anti-dripping agents, and other additives typically used with such polymers. In some embodiments, the additional flame retardant additive may be a complementary flame retardant such as, but not limited to, alumina trihydrate, magnesium hydroxide, organic sulfonate or sulfonamidate salts, siloxanes, (organic) phosphinate salts, metal phosphinate salts, ammonium polyphosphate, melamine, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, melamine cyanurate, red phosphorus, (poly)phosphonates, triphenyl phosphate, or a bisphosphate flame retardant (such as resorcinol bis(diphenyl phosphate), or bisphenol A bis(diphenyl phosphate).
In certain embodiments, the amino terminated phosphonamide or oligomeric amino-terminated phosphonamide may be formulated as fiber reinforced composites. Such fiber reinforced composites may include any of the thermoplastics or thermosets described herein in combination with a fiber or fabric that may be composed of carbon, glass, organic fibers such as polyester, polyaramide, inorganic fibers may include, but are not limited to, silicon carbide. In some embodiments, the reinforcing fiber or fabric may be incorporated into the polymer matrix with the amino terminated phosphonamide or oligomeric amino-terminated phosphonamide, and in other embodiments, the polymer resin, amino terminated phosphonamide or oligomeric amino-terminated phosphonamide can be used to impregnate a reinforcing fiber or fabric.
In particular embodiments, the oligomeric amino-terminated phosphonamide may be provided in epoxy formulations. Such embodiments are not limited to any particular type of epoxy. For example, the epoxy resin may be a bisphenol A epoxy, bisphenol F epoxy, phenolic novolak epoxy, cresol novolak epoxy, bisphenol A novolak epoxy resins, and the like. In some embodiments, the epoxy resins used in embodiments may be halogenated, and in other embodiments, the epoxy resins may be non-halogenated. Such epoxy resins may be used in any application. The epoxies of such embodiments including oligomeric amino-terminated phosphonamides may be incorporated into, for example, circuit boards, housing for electronic components, epoxy encapsulant compositions for use in electronic applications, and in other embodiments, epoxy compositions of the invention can be used for structural applications and as coatings. The oligomeric amino-terminated phosphonamides can be used in place of brominated flame retardants or other phosphorus containing flame retardants, or the oligomeric amino-terminated phosphonamides can be used in combination with such compositions. In some embodiments, epoxy resins compositions including oligomeric amino-terminated phosphonamides may contain other components conventionally used epoxies such as, but not limited to, polyphenylene oxide, imide, phenolic, and benzoxazine resins as well as reinforcement additives such as paper, glass fibers, organic fibers, or carbon fibers.
In some embodiments, the oligomeric amino-terminated phosphonamide of the invention may be used in combination with polyurea. The oligomeric amino-terminated phosphonamides can be incorporated into any polyurea formulation known in the art. For example, in certain embodiments, the polyurea formulations may include diisocyanates, aromatic or aliphatic diamines, or combinations thereof in addition to the amino terminated phosphonamide.
In some embodiments, the oligomeric amino-terminated phosphonamide may be used in crosslinked polymer compositions. In some embodiments, an oligomeric amino-terminated phosphonamides having two or more functional amine groups per oligomer chain such as, but not limited to, those described in Formula I and Formula II can act as a crosslinking agent. These oligomeric amino-terminated phosphonamides can be combined with a thermoplastic or thermoset resin having functional groups that can react with the amine groups of the oligomeric amino-terminated phosphonamide. For example, in particular exemplary embodiments, crosslinked polyureas can be produced by combining polyureas with the amino terminated phosphonamides of embodiments of the invention, and, for example, triisocyanates, diisocyanates, aromatic or aliphatic diamines, or combinations thereof.
In some embodiments, the oligomeric amino terminated phosphonamides can be mixed or blended with other monomers, oligomers, or polymers and these mixtures can be used for preparing articles of manufacture from the blended material. For example, some embodiments include methods for preparing a polymer composition including the steps of blending in a melt a monomer, oligomer, or polymer and a oligomeric amino terminated phosphonamide. The melt blending may be carried out by any mixing technique, for example, melt mixing may be carried out in a brabender mixer or extruder. In some embodiments, the methods may include the steps of extruding the mixture after melt mixing and pelletizing the resulting material. In other embodiments, the methods may include compressing the melt mixed material in rollers to create a film, spincasting a film, blowmolding a film or extruding a sheet product. In still other embodiments, the methods may include molding the melt mixed material into an article of manufacture. In still other embodiments the oligomeric amino terminated phosphonamide can be mixed in solution with other components and, optionally after mixing with another solution, be sprayed to form a film.
Still other embodiments include polymeric compositions prepared from these amino terminated phosphonamide oligomers and other monomers, oligomers or polymers that meet UL fire or comparable standardized fire resistance ratings required for a variety of consumer products without detracting from other important safety, environmental, manufacturing and consumer use requirements. For example, consumer electronics must meet particular fire resistance standards as specified by the Underwriter's Laboratory (UL) or comparable standardized fire resistance rating criteria without compromising other properties such as Tg, HDT, and interfacial adhesion. The electronics often contain circuit boards that include epoxy/glass laminates. The state-of-the-art approach to rendering these systems flame retardant is to use various additives such as brominated compounds or compounds containing aluminum, antimony, and/or phosphorus. However, these compounds are often toxic, and can leach into the environment over time making their use less desirable. In some countries these additives and related additive types are being phased out of use.
Further embodiments include articles of manufacture that include a polymer matrix and the amino terminated phosphonamide or oligomeric amino-terminated phosphonamide of the invention. For example, certain embodiments are directed to consumer electronics and other consumer products that must meet particular fire resistance standards as specified by UL or other standardized criteria. Such consumer electronics and consumer products may contain or include, for example, circuit boards, housings, or other components or subcomponents that include amino terminated phosphonamide or oligomeric amino-terminated phosphonamide containing compositions, filled amino terminated phosphonamide or oligomeric amino-terminated phosphonamide containing compositions, or fiber reinforced amino terminated phosphonamide or oligomeric amino-terminated phosphonamide compositions. The components fabricated from such compositions will generally meet the UI-94 V-0 or similar criteria for fire resistance while retaining good properties such as Tg, HDT, interfacial adhesion, and the like.
EXAMPLES
Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other versions are possible. Therefore the spirit and scope of the appended claims should not be limited to the description and the preferred versions contained within this specification. Various aspects of the present invention will be illustrated with reference to the following non-limiting examples.
Materials
JEFFAMINE diamines (D230, D2000 and T403) were purchased from Huntsman Petrochemical Corporation. Expandable graphite—GRAFGUARD® 160-50 was obtained from GrafTech International. Ammonium polyphosphonate (APP) (20 μm powder) was obtained from ICL-LP. Diphenyl methyl phosphonate (DPP) was prepared using methods referred to in U.S. Pat. No. 7,888,534 B2 and U.S. Pat. No. 7,928,259 B2, Dragonshield-BC (DSBC™) was obtained from Specialty Products Inc. (SPI).
Example 1
Preparation of Oligomeric Amino Terminated Phosphonamides
The reactions of various aromatic and aliphatic diamines with diphenylmethyl phosphonate were carried out in a round bottom flask fitted with a mechanical stirrer, N 2 /vacuum inlet, and a distillation column (filled with hollow glass tubes) wrapped with electrical heating tape. The reagents were heated to 200° C. for 12-14 hrs., while gradually lowering the vacuum from 400 mmHg to 5 mmHg. The temperature was then increased to 240° C. for 4-6 hrs at <1 mmHg (full vacuum) to drive off residual phenol and any unreacted starting materials. The amino terminated phosphonamide product was isolated as a viscous liquid. The reaction was monitored by gas chromatography-mass spectroscopy (GC-MS) by analysis of the phenol by-product. The amino terminated phosphonamide oligomer was analyzed using nuclear magnetic resonance spectroscopy ( 1 H-NMR) and the % phosphorus was determined using inductively coupled plasma optical emission spectrometry (ICP-OES).
Example 2
Synthesis of an Amino Terminated Phosphonamide
276.0 g (1.2 mol) JEFFAMINE D230, 297.8 g (1.2 mol) DPP and 3.05 g (0.03 mol) magnesium chloride were added to a 1 L round bottom flask and heated to 200° C. while stirring for 14 hours. The vacuum was gradually lowered to 60 mmHg over 6 hrs., maintained at 40 mm Hg for 4 hrs, and then lowered to 10 mmHg for 4 hrs. The distillation column was maintained at 115° C. for 14 hrs. The distillate was collected in a flask cooled in ice. After 14 hours, full vacuum was applied (<0.5 mmHg) and the temperature increased to 240° C. for 2.5 hrs. The product was isolated as a highly viscous liquid (320.6 g). GC-MS analysis of the distillate indicated the total phenol collected was 170.3 g (1.8 mol), residual diamine 23.2 g (0.1 mol) and residual DPP collected was 53.7 g (0.2 mol). Anal. % P=10.6 wt. %.
Example 3
Synthesis of an Amino Terminated Phosphonamide
301.3 g (1.31 mol) JEFFAMINE D230, 259.3 g (1.05 mol) DPP and 3.05 g (0.03 mol) magnesium chloride were added to a 1 L round bottom flask and heated to 200° C. while stirring for 19 hours. The vacuum was gradually lowered to 60 mmHg over 9 hrs., and then lowered to 3.0 mmHg over 5 hrs. and held for 4 hrs. The distillation column was maintained at 115° C. The distillate was collected in a flask cooled in ice. After 19 hours, full vacuum was applied (<0.5 mm Hg) and the temperature increased to 230° C. for 1 hr. The product was isolated as a highly viscous liquid (276.3 g). GC-MS analysis of the distillate indicated the total phenol collected was 178.3 g (1.9 mol), residual diamine 66.7 g (0.3 mol) and residual DPP collected was 24.5 g (0.1 mol). Molecular weight (Mw 670, Mn 570) (GPC, PS standards). Anal. % P=10.4 wt. %.
Example 4
Synthesis of an Amino Terminated Phosphonamide
956.2 g (0.48 mol) JEFFAMINE D2000, 109.2 (0.44 mol) DPP and 2.67 g (0.028 mol) magnesium chloride were added to a 3 L round bottom flask and heated to 200° C. while stirring for 18.5 hours. The vacuum was gradually lowered to 20 mmHg over 3 hrs. and held for 11.5 hrs., and then to 5 mm Hg for 4 hrs. The distillation column was maintained at 115° C. for 6.5 hrs. and then increased to 140° C. The distillate was collected in a flask cooled in ice. After 18.5 hrs., full vacuum was applied (<0.5 mm Hg) for 4.5 hrs. at 200° C. Then, the temperature increased to 215° C. for 1.0 hr., and to 240° C. for 2.5 hrs. The product was isolated as a highly viscous liquid (969 g). GC-MS analysis of the distillate indicated the total phenol collected was 66.2 g (0.7 mol), and residual DPP collected was 13.6 g (0.05 mol). Anal. % P=1.3 wt. %.
Example 5
Synthesis of an Amino Terminated Phosphonamide
175.0 g (0.39 mol) JEFFAMINE T403, 124.1 g (0.5 mol) DPP and 1.24 g (0.013 mol) magnesium chloride were added to a 500 mL round bottom flask and heated to 200° C. while stirring for 7 hours. The vacuum was gradually lowered to 55 mmHg over 2 hrs, then to 5 mm Hg over 5 hrs. The distillation column was maintained at 115° C. The distillate was collected in a flask cooled in ice. After 7 hrs., full vacuum was applied (0.1 mm Hg) for 2 hrs at 200° C., and then increased to 250° C. for 2 hrs. After 2 hrs. the product cross-linked in the flask and the reaction was discontinued. The product was removed from the flask by breaking the flask and 48.1 g of solid was recoverable. Total phenol collected was 73.0 g (0.8 mol), and residual unreacted triamine 9.6 g (0.02 mol) and 17.6 g DPP (0.07 mol). Anal. % P=6.5 wt %.
Example 6
Synthesis of an Amino Terminated Phosphonamide
175.0 g (0.39 mol) JEFFAMINE T403, 124.1 g (0.5 mol) DPP and 1.24 g (0.013 mol) magnesium chloride were added to a 500 mL round bottom flask and heated to 200° C. while stirring for 14 hours. The vacuum was gradually lowered to 25 mmHg over 3 hrs., then to 5 mm Hg for 11 hrs. The distillation column was maintained at 115° C. The distillate was collected in a flask cooled in ice. After 14 hrs., full vacuum was applied (<0.5 mm Hg) for 4.5 hrs. at 200° C. The product was isolated as a solid (219.1 g). GC-MS analysis of the distillate indicated the total phenol collected was 72.3 g (0.8 mol), and no residual triamine or DPP was collected. Anal. % P=7.3 wt. %.
Example 7
Synthesis of an Amino Terminated Phosphonamide
1789 g (0.90 mol) JEFFAMINE D2000, 203 g (0.82 mol) DPP and 0.5 g (0.005 mol) magnesium chloride were added to a 3 L round bottom flask and heated to 200° C. while stirring under vacuum (250 mmHg). After 4.5 hrs, the vacuum was gradually lowered to 10 mmHg over 8 hrs. and then to 5 mm Hg for 4 hrs. After 16.5 hrs., full vacuum was applied (<0.5 mm Hg), and the temperature increased to 225° C. for 1.0 hr. and then to 240° C. for 3.5 hrs. The distillation column was maintained at 115° C. for 16.5 hrs. and then increased to 140° C. The distillate was collected in a flask cooled in ice. The product was isolated as a highly viscous liquid (1855 g). GC-MS analysis of the distillate indicated the total phenol collected was 123.6 (1.31 mol), and residual DPP collected was 0.4 g (0.002 mol). Anal. % P=1.3 wt. %.
Example 8
Synthesis of an Amino Terminated Phosphonamide
1789 g (0.90 mol) JEFFAMINE D2000, 203 g (0.82 mol) DPP and 0.5 g (0.005 mol) magnesium chloride were added to a 3 L round bottom flask and heated to 200° C. while stirring under vacuum (250 mmHg). After 4.5 hrs., the vacuum was gradually lowered to 10 mmHg over 8 hrs and then to 5 mm Hg for 4 hrs. After 16.5 hrs., full vacuum was applied (<0.5 mm Hg), and the temperature increased to 225° C. for 1.0 hr., and then to 240° C. for 3.5 hrs. The distillation column was maintained at 115° C. for 16.5 hrs. and then increased to 140° C. The distillate was collected in a flask cooled in ice. The product was isolated as a highly viscous liquid (1843 g). GC-MS analysis of the distillate indicated the total phenol collected was 90.2 g (0.96 mol), and residual DPP collected was 19.0 g (0.08 mol). Anal. % P=1.3 wt. %.
Example 9
Amino Terminated Phosphonamide Oligomers in Polyureas
Polyurea formulations are generally prepared by the reaction of diamines with diisocyanates. In order to produce flame retardant polyureas, several phosphorus based diamines (FZX diamines) were prepared and added to the diamine formulations used to prepare blast mitigation coatings. (Scheme 1).
Example 10
Polyurea Films with Amine Terminated Phosphonamide Oligomers
Polyurea films were prepared by spraying out a combination of diisocyanates (A-side) and diamines (B-side) onto primed concrete boards of 6 inches×18 inches for flammability testing. The thickness of each coating was 90 mils (0.09 inches). The test was conducted in accordance with the ASTM E-162, “Standard Method of Test for Surface Flammability of Materials Using a Radiant Heat Energy Source.” The spray-coated boards are mounted in a frame placed facing the radiant panel, but inclined at an angle of 30 degrees from top downward. A pilot burner adjusted to provide a 6″ to 7″ flame serves to ignite the sample at the top. The material under test burns downward.
Oligomeric amine terminated phosphonamides were added to the B-side of the mixture during formulation. Phosphorus-based additives—diphenyl methylphosphate (DPP) and ammonium polyphosphate (APP)—were also tested as additives in the A-side and the B-side, respectively. Graphite was added to various formulations to prevent dripping during burning. The base formulation was Dragonshield BC™ (DSBC™).
DSBC™ Formulations containing the commercial flame retardant additive ammonium polyphosphonate (APP) were prepared and evaluated in comparison to phosphonamide oligomers. Due to processability during formulation, the optimal loading of the amine-terminated phosphonamide oligomer PA-D2000 was 17 wt. %.
Tables 1-2 provide results from ASTM E162 testing of the FR polyurea samples. The results are recorded as a Flamespread Index determined from progression time of the flame at 3, 6, 9, 12, and 15 inch interval marks measured from the top of the sample. The maximum temperature increase resulting from the burning sample was measured by 8 thermocouples connected in parallel and located in the sheet metal stack above the tested sample. The Flamespread Index (FSI) is derived by the following formula:
Is=Fs×Q
where Is is the Flamespread Index, Fs is the Flamespread Factor, and Q is the Heat Evolution Factor. The flamespread classification system used by most of the model building codes and the National Fire Protection Association Life Safety Code, NFPA No. 101, encompasses the following:
Class A (I)—0 to 25 Flamespread Index
Class B (II)—26 to 75 Flamespread Index
Class C (III)—76 to 100 Flamespread Index
The results of FSI testing of various polyurea compositions including oligomeric amino-terminated phosphonamides are provided in Table 1.
TABLE 1
Polyurea FR Testing: Flame Spread Index (FSI) Results
Wt % Additives in DSBC ™ Formulation
B-Side
A-Side
PA-D2000
Total
ASTM
FSI
#
DPP
Graphite
(Example 3)
APP
% P
E162
Class
1
0
0
0
0
0
212
Fail
2
0
2
0
10
1.0
114
Fail
3
0
5
0
10
1.0
64
B
4
0
5
0
20
2.6
54
B
5
0
5
17
0
0.1
89
C
6
8
5
0
10
1.5
70
B
7
8
5
17
0
0.6
47
B
TABLE 2
Polyurea FR Testing: Flame Spread Index (FSI) Results
Wt % Additives in DSBC ™ Formulation
B-Side
A-Side
PA-D2000
Total
ASTM
FSI
#
DPP
Graphite
(Example 6)
APP
% P
E162
Class
1
0
0
0
0
0
212
Fail
2
0
10
0
2
0.3
34
B
3
8
10
17
2
0.9
13
A
Example 11
Evaluation of FR Behavior of Phosphonamides in Bisphenol-A Epoxies
The FR performance of cured epoxy resin samples with and without phosphonamides was evaluated, and the results are provided in Table 3. The samples were prepared by mixing the amine-terminated phosphonamide oligomers with the epoxy resin and curing in an oven at 60° C. for 48 hr. The FR was evaluated by holding a flame to the sample for 10 seconds and observing for self-extinguishing behavior. The formulation containing the amine terminated phosphonamide oligomer (PA-D230 Example 2) exhibited self-extinguishing behavior, whereas the formulation containing the diamine (D230) continued to burn.
TABLE 3
Epoxy formulations with phosphonamides
Amine-terminated
PA-D230
compound
D230
(Example 2)
Weight (g)
6.5
6.5
Epoxy resin (g)
5
5
Diethyl triamine (g)
0
0.5
Total % P
0
5.6
FR evaluation—
no
yes
Self-extinguishing
|
The invention relates to the use of amino terminated phosphonamides and their oligomers, as flame retardant additives for a variety of polymers to impart flame retardancy while maintaining or improving processing characteristics and other important properties.
| 2
|
BACKGROUND
[0001] Portable generators for producing electricity are well known and have been commercially available for many years. These devices typically include an internal combustion engine, are designed to generate sufficient electrical power to run one or more common household or commercial electronic devices, and typically use gasoline as fuel. They are adapted to provide alternating current (AC) electricity, through a standard two-prong or three-prong plug receiver, at 120 or 240 volts, and at 50 to 60 Hz; also common is an additional 12 volt DC power port for charging lead acid batteries. Many of these devices are not fuel injected and include a carburetor and a manual choke. Fuel is delivered to the carburetor with the aid of a fuel pump or by gravity. The carburetor mixes the fuel with air before it enters the cylinder. In the cylinder, the fuel-air mixture is ignited by a catalytic spark from a spark plug. Combustion of the fuel then drives the engine.
[0002] Diesel generators are also known. They operate in a similar fashion to gasoline generators, except a spark plug is not used to ignite the fuel-air mixture. Rather, compression of the fuel-air mixture with the cylinder causes auto-ignition and in some cases a glow-plug is added to enhance cold starting operation
[0003] Some of the smallest commercially available portable generators include the YAMAHA Inverter EF1000iS and the HONDA EU1000i. The capacity of the fuel tanks in these types of devices is about 0.6 gallons of gasoline, allowing operation at the maximum load of around 1000 W of 4 to 6 hours, or at ¼ load for 8 to 12 hours. These generators produce less noise than larger models, having a typical sound output of 47 to 59 dB. These devices include an internal combustion engine using gasoline fuel, so they necessarily generate carbon monoxide (CO), and do not come equipped with a catalytic converter or CO safety shut down features. Thus the manufactures strongly discourage indoor use because of the danger of carbon monoxide poisoning to humans and animals.
[0004] There has been a proliferation of small portable electronic devices and electric vehicles in recent years, most of which include small onboard rechargeable batteries. Examples include laptop computers, scooters, mobile telephones, personal digital assistants, portable digital cameras, golf carts and global positioning systems. The rechargeable batteries are most commonly lithium ion and lead acid batteries, although other varieties are available. The small portable electronic devices typically include a removable power cord with a standard two-prong or three-prong plug, or a universal serial bus (USB) plug, for plugging into a corresponding plug receiver, which allows for recharging the rechargeable batteries. Also commonly available are removable power cords with a standard cigarette lighter plug, for recharging the rechargeable batteries using a cigarette lighter plug receiver in an automobile or other vehicle.
[0005] For field operation by consumers of portable appliances such as televisions and radios, and small portable electronic devices and recharging of the batteries therein, portable generators have come into common use. Although an automobile is used to get to the field location for camping or tailgating, and is therefore available for recharging batteries or for providing DC power, unless the engine and alternator are running there is a risk of draining the automobile battery, and compromising the operation or starting capacity of the automobile. If the engine is running, over extended periods of time, there will be substantial use of the gasoline from the fuel storage tank, far in excess of the amount of electricity needed to recharge batteries for small portable electronic devices. This results because the rechargeable batteries require a specific amount of time and power to recharge, and even when just idling the vehicle engine consumes far more fuel than necessary to recharge the batteries. The advantage of using a portable generator is the much greater efficiency for generating the amount of electricity needed to recharge batteries, over the period of time necessary for recharging, as compared to an automobile engine. In other words, there is a superior match between the power generation and the power consumption. However, there is still a significant mismatch between the amount of power produced by even the smallest commercially available portable generators and small portable electronic devices and the small rechargeable batteries they contain.
[0006] Often, remote field location operations are staged, first setting up a base camp, next a remote camp, and lastly individuals on foot or with only a single vehicle are sent even farther afield. Remote field location operations are therefore required to carry all supplies, especially consumable supplies, which will be needed. Not only is the total amount of supplies often minimized to reduce cost and weight, but the variety of supplies is also minimized, to reduce logistical costs and complexity in transporting materials to, and resupplying, the base camp.
[0007] To get to remote field locations, such as those in wilderness areas far away from highways, vehicles which use diesel fuel, rather than gasoline are commonly used. The supplies carried to such remote field locations only include diesel fuel, not gasoline, for the vehicles. In these cases, recharging of batteries is carried out using power generated by the vehicle, keeping the vehicle engine running while recharging the batteries or from a large 2-10 kW diesel generator carried by the vehicle. As noted above, a vehicle engine and alternator is especially inefficient for recharging small batteries. Lastly, unless constantly monitored the vehicle engine or diesel generator will continue running even if the batteries have completed recharging, continuing the consumption of diesel fuel until human intervention or until all of the fuel is consumed. Under these circumstances, the use of diesel fuel and a generator or vehicle engine and vehicle alternator is particularly inefficient for recharging small batteries.
[0008] To address this inefficient use of diesel fuel in remote field location operations, other energy sources have been used, but each suffers from drawbacks. Solar power units are available, but they tend to be large and require significant set up time to spread out the solar cells for sufficient energy generation. Furthermore, sun light is only available during the day, and unpredictable cloud cover can make the availability of solar power unreliable and intermittent over the time scale of remote field location operations. Wind power is potentially available night and day, but otherwise can require similarly bulky equipment and can be similarly unreliable and intermittent.
[0009] In order to address the needs of remote field location operations for small amounts of electrical power over an extended period of time for both the operation of, and recharging of batteries within, small portable electronic devices or small electric vehicles, small portable generators including an internal combustion engine has been considered. However, such devices still suffer from many of the disadvantages of using a vehicle engine or large diesel generator. Although the use of fuel over any specific period of time is less, the small portable generators still continue to run when recharging of batteries is completed unless constantly monitored. A further disadvantage is that an additional fuel, such as gasoline, is needed since small portable generators typically do not use the same fuel as diesel vehicles, complicating the supply logistics by adding to the total amount and variety of materials.
SUMMARY
[0010] In a first aspect, the present invention is a method for efficient fuel consumption, comprising: recharging batteries or operating a device carrying out a task, with an engine through an electrical connection, while monitoring at least one of (i) current in the electrical connection, (ii) voltage of the batteries, and (iii) length of time of the recharging or task, to determine if the recharging has reach a preselected endpoint or the task has been completed; and generating a signal through a communication link to cause the engine to stop operating by: (a) preventing operation of a spark plug, (b) preventing delivery of fuel to the engine, or (c) preventing delivery of oxygen to the engine.
[0011] In a second aspect, the present invention is a method for efficient fuel consumption, comprising: recharging batteries with an engine through an electrical connection, while monitoring at least one of (i) current in the electrical connection, (ii) voltage of the batteries and (iii) length of time of the recharging, to determine if the recharging has reach a preselected endpoint; and generating a signal to a user indicating that the preselected endpoint has been reached. The preselected endpoint occurs when the batteries are less than 100% recharged.
[0012] In a third aspect, the present invention is a method for efficient fuel consumption, comprising: recharging batteries or operating a device carrying out a task, with an engine through an electrical connection, while monitoring at least one of (i) current in the electrical connection, (ii) voltage of the batteries and (iii) length of time of the recharging or task, to determine if the recharging has reach a preselected endpoint or the task has been completed; and generating a signal to a user indicating that the preselected endpoint has been reached or the task has been completed. The signal is at least one member selected from the group consisting of a wireless message sent to an electronic device carried by the user, and sound having a volume of at least 40 dB.
[0013] In a fourth aspect, the present invention is a device for efficient fuel consumption by an engine recharging at least one battery or operating a device carrying out a task, comprising: a monitor, for monitoring a stage of recharging of the at least one battery or completion of the task, and an effector, for generating a signal when a preselected stage of recharging of the at least one battery has been reached or the task has been completed. The monitor comprises at least one member selected from the group consisting of an ammeter and a volt meter.
[0014] In a fifth aspect, the present invention is a device for efficient fuel consumption by an engine recharging at least one battery or operating a device carrying out a task, comprising: a monitor, for monitoring a stage of recharging of the at least one battery or completion of the task, an effector, for generating a signal when a preselected stage of recharging of the at least one battery has been reached or the task has been completed, and a communication link adapted for sending the signal from the effector to the engine, for stopping the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a graph showing current (amperage) and voltage versus time for recharging a battery.
[0016] FIG. 2 illustrates a device for efficient fuel consumption.
[0017] FIGS. 3-9 illustrated a variety of devices, systems and configurations for efficient fuel consumption.
DETAILED DESCRIPTION
[0018] In order to avoid wasting fuel, the generator or vehicle engine should be turned off once a task, such as recharging batteries or operating an electronic device, has been completed. However, having a person monitor the recharging process or a device carrying out a task can be inconvenient. The present invention makes use of the discovery that efficient fuel consumption may be realized by purposefully ending the operation of a generator or engine without requiring continuous monitoring by a person. Efficient fuel consumption is achieved by ending operation of the generator or engine when, for example, charging is competed or the first stage of recharging is completed for rechargeable batteries, or when devices have completed a task. When the operation of the generator or engine is ended may be determined by monitoring the passage of a specific amount of time, or by monitoring current, voltage and/or power flowing to a load, such as a rechargeable battery and/or an electronic device. The generator or vehicle engine may be stopped by, for example, providing a signal to a person, or automatically, for example, by stopping the flow of fuel or air to the generator or vehicle engine, or cutting power to a spark plug, for example by grounding the spark plug.
[0019] FIG. 1 is a graph showing current (amperage) and voltage versus time for recharging a battery. The figure is a qualitative diagram for a lead acid battery, but almost any rechargeable batter, such as a lithium ion battery or nickel cadmium battery, will exhibit similar stages. The three stages are labeled bulk (the first stage), absorption (the second stage) and maintenance (the third stage). When any battery is recharged from a state when less than 75%, preferably less than 50%, most preferably less than 25%, including less than 5%, of the total amount of energy which the battery can store is left available in the battery, it will typically first go through the bulk stage of recharging, followed by the absorption stage of recharging. The final stage, maintenance, will be entered just before, or just after, the battery is fully recharged. For any rechargeable battery, the characteristic voltage, current and/or power consumption of each of the stages may be easily determined by monitoring one or more of these characteristics in the electrical connection between a power source, such as a generator or vehicle engine, and a battery which is being recharged from a discharged state.
[0020] As illustrated in FIG. 1 , the first stage of recharging consumes the most power. The current flowing to the battery is the greatest during this stage, and the voltage typically increases gradually towards a maximum value reached during recharging. Since the most power is consumed during this stage of recharging, the power output of a generator or vehicle engine will be most closely matched with the power consumed by the recharging process. Fuel is most efficiently consumed during this stage of recharging. This stage is completed, for example, when the battery is about 90% recharged.
[0021] As illustrated in FIG. 1 , the second stage of recharging, absorption, exhibits a significant drop in current, and voltage will be steady or almost steady at a maximum value. The amount of power consumed during this stage is significantly less than the amount of power consumed during the first stage, so the mismatch of the power output of a generator or vehicle engine is substantially greater than during the first stage of recharging. Fuel is much less efficiently consumed during this stage, as compared to the first stage of recharging. Depending on the desired efficiency of fuel consumption, it may be desirable to end recharging of a battery at a time just before, to just after, entering the second stage. This stage is completed, for example, when the battery is about 99% recharged.
[0022] As illustrated in FIG. 1 , the third stage of recharging, maintenance, exhibits a further significant drop in current; voltage may also drop during maintenance (as illustrated) or voltage may be maintained at or near a maximum value. The third stage is reached just before, or at the point when, a battery is fully recharged. Fuel is no longer being efficiently used or is being wasted, during this third stage of recharging. It is always desirable to end recharging of a battery a time before, to just after, entering the third stage.
[0023] Since any generator or vehicle engine may produce more power than a recharging battery consumes during any of the three stages, each stage will also have a characteristic duration for each type of battery. For any rechargeable battery, the characteristic duration of each of the three stages may easily be determined by monitoring one or more characteristics in the electrical connection between a power source, such as a generator or vehicle engine, and a battery which is being recharged from a discharged state.
[0024] Similarly, when a device has completed a task, there will be a significant decrease in the voltage or current flowing to the device. Furthermore, a device may complete a task in a characteristic period of time. Stopping the operation of the engine supplying electricity to the device when the task has completed, either based on the voltage, current or period of time, will increase efficiency.
[0025] FIG. 2 illustrates a device for efficient fuel consumption, 1 . The device includes a monitor, 3 , and an effector, 7 , which are in communication. These two elements may be integrated together, or may be connect via an electrical connection, 5 . The monitor and the effector could also be in communication through a wireless connection, or through a network connection, such as a local area network or the internet.
[0026] The monitor is the element of the device which determines when the generator or vehicle engine should be stopped, or determines the stage of the recharging operation. The monitor may monitor current flowing to the battery, and may include an ammeter, preferably an inductive ammeter; the monitor may monitor voltage of the battery, and may include a voltmeter; the monitor may monitor power consumed by the recharging operation, and may include both an ammeter and a voltmeter. Alternatively, the monitor may include a clock or timer, to measure duration to determine the stage of the recharging operation. Combinations of these devices may also be used.
[0027] The effector generates a signal to stop the operation of the generator or vehicle engine. For example, the effector may produce a sound, such as special tone or musical passage, or a noise, which indicates to a person to end the operation of the generator or vehicle engine; or the effector may send a message, such as a text message to a mobile telephone, or a message to a pager which indicates to a person carrying the mobile telephone or pager to end the operation of the generator or vehicle engine.
[0028] Alternatively, the effector may be in communication with a device which will end the operation of the generator or vehicle engine. For example, some generators and vehicles come equipped with a remote start-stop device, through which the effector may directly stop the generator or vehicle engine. Alternatively, the effector could activate a switch which stops a fuel pump or interrupts or grounds the electrical connection of a spark plug to a power source, or the effector could stop operation of a generator or vehicle engine by interrupting the supply of air or oxygen to the engine. Combinations may also be used.
[0029] The oxidation products of the internal combustion process from a generator or vehicle engine, including carbon dioxide, carbon monoxide, and some trace organics, are of concern. Accumulation of carbon monoxide, even in small amounts, is poisonous to humans and animals. Optionally, a carbon monoxide sensor may also be included in the device, 1 , for detecting the level of carbon monoxide. The detector may set off an alarm when the level of carbon monoxide approaches, or reaches, a dangerous concentration. In addition to an alarm, or instead of an alarm, the carbon monoxide detector may cause the effector to notify a person, or cause the effector to directly turn off the generator or vehicle engine, when the level of carbon monoxide approaches, or reaches, a dangerous concentration.
[0030] Optionally, the device may also include the electrical connection, such as extension cord or cable, which connects the generator or vehicle engine with the load including rechargeable batteries, and/or an electrical connection to the on/off switch of the generator or vehicle engine. Each of the monitor, the effector, and/or the electrical connection of the device may include application specific integrated circuits (ASIC), electronic circuits, logic circuits, processors, computers, memory, wireless communication elements, internet connections and/or other suitable components that may execute one or more software and/or firmware programs.
[0031] FIGS. 3-9 illustrate devices, systems and configurations for efficient fuel consumption. FIG. 3 illustrate system or configuration, 10 , for efficient fuel consumption. Included in the figure is fuel containing generator or vehicle, 12 , and load, 20 . The load may be one or more rechargeable batteries, optionally contained in or connected to one or more electronic devices. Device, 16 , includes a monitor and an effector. Electrical connections, 14 and 18 , electrically connect the generator or vehicle to the load; the device may also be electrically connected to the generator or vehicle, and the load, via the electrical connections, or may be sufficiently proximate to the electrical connections, for monitoring the current, voltage or power of the recharging operation. In another configuration, such as when the monitor is monitoring the duration of the recharging operation, the device may be spaced away from the electrical connections. Also illustrated is a communication link, 22 , between the device and the generator or vehicle; the communication link may be an electrical connection or may be a wireless connection, for stopping the operation of the generator or vehicle engine. In operation, when the monitor within the device, 16 , determines that the recharging operation is nearing the end of the first stage, or entering or beginning the second stage, the effector will cause the generator or vehicle engine to stop operation, through the communication link, 22 , thereby stopping the further consumption of fuel by the generator or vehicle, 12 . Alternatively, when the monitor within the device, 16 , determines that the recharging operation is nearing the end of the second stage, or entering or beginning the third stage, the effector will cause the generator or vehicle engine to stop operation, through the communication link, 22 , thereby stopping the further consumption of fuel by the generator or vehicle, 12 .
[0032] FIG. 4 illustrates system or configuration, 30 , for efficient fuel consumption. Included in the figure are generator or vehicle, 32 , and load, 40 . The load may be one or more rechargeable batteries, optionally contained in or connected to one or more electronic devices. Device, 36 , includes a monitor and an effector. Electrical connections, 34 and 38 , electrically connect the generator or vehicle to the load; the device may also be electrically connected to the generator or vehicle, and the load, via the electrical connections, or may be sufficiently proximate to the electrical connections, for monitoring the current, voltage or power of the recharging operation. In another configuration, such as when the monitor is monitoring the duration of the recharging operation, the device may be spaced away from the electrical connections. Also illustrated is a person, 42 , who is neither monitoring the recharging operation nor monitoring the device. In operation, when the monitor within the device, 36 , determines that the recharging operation is nearing the end of the first stage, or entering or beginning the second stage, the effector will issue a sound, preferably louder than the generator or vehicle engine, for example louder than 47 to 59 dB, or send a message, such as a text message to a mobile telephone, or a message to a pager, to notify the person to turn off the generator or vehicle engine, thereby stopping the further consumption of fuel by the generator or vehicle, 32 . Alternatively but less preferably, when the monitor within the device, 36 , determines that the recharging operation is nearing the end of the second stage, or entering or beginning the third stage, the effector will issue a sound, preferably louder than the generator or vehicle engine, for example louder than 47 to 59 dB, or send a message, such as a text message to a mobile telephone or a message to a pager carried by the person, to notify the person to turn off the generator or vehicle engine, thereby stopping the further consumption of fuel by the generator or vehicle, 32 . Preferably, the effector within the device, 36 , does not use a visual signal such as a color change on a light emitting diode, emanating from the device, to notify the person. Preferably, the effector within the device, 36 , does not use a quiet sound, for example having a loudness of less than 40 dB, to notify the person. The sound or signal from the device, 36 , is distinct from any sound or signal issued by the load, 40 , which indicates completion of recharging.
[0033] FIG. 5 illustrate system or configuration, 50 , for efficient fuel consumption. Included in the figure is fuel containing generator or vehicle, 52 , a load, 62 , and one or more power storage batteries, 64 . Preferably, the load may be one or more lithium ion or nickel cadmium rechargeable batteries, optionally contained in or connected to one or more electronic devices. Preferably, the power storage batteries are lead acid batteries. Device, 56 , includes a monitor and an effector. Electrical connections, 54 and 60 , electrically connect the generator or vehicle to the load, and electrical connections 54 and 58 electrically connect the generator or vehicle to the power storage batteries; the device may also be electrically connected to the generator or vehicle, the load, and the power storage batteries, via the electrical connections, or may be sufficiently proximate to the electrical connections, for monitoring the current, voltage or power of the recharging operations. Electrical connection 60 is optional. In another configuration, such as when the monitor is monitoring the duration of the recharging operation, the device may be spaced away from the electrical connections. Another electrical connection, 66 , is present between the load and the power storage batteries. Also illustrated is a communication link, 68 , between the device and the generator or vehicle; the communication link may be an electrical connection or may be a wireless connection, for stopping the operation of the generator or vehicle engine.
[0034] In the configuration of FIG. 5 , in contrast to the configuration of FIG. 3 , two recharging operations are taking place: recharging of the rechargeable batteries present in the load, 62 , and the rechargeable batteries present in the power storage batteries, 64 . The monitor present in the device, 56 , may monitor both recharging operations, or alternatively may only monitor the recharging of the power storage batteries, 64 . In operation, when the monitor within the device, 56 , determines that one or both recharging operations is nearing the end of the first stage, or entering or beginning the second stage, the effector will cause the generator or vehicle engine to stop operation, through the communication link, 68 , thereby stopping the further consumption of fuel by the generator or vehicle, 52 . Alternatively, when the monitor within the device, 56 , determines that one or both recharging operations is nearing the end of the second stage, or entering or beginning the third stage, the effector will cause the generator or vehicle engine to stop operation, through the communication link, 68 , thereby stopping the further consumption of fuel by the generator or vehicle, 52 .
[0035] The inclusion of the power storage batteries, 64 , can improve the efficiency of the system. For example, the power output of a generator or vehicle engine will be more closely matched with the power consumed by recharging the power storage batteries alone (in the case of lead acid batteries for the power storage batteries and lithium ion batteries for the load) or the combination of the power storage batteries and the load, as compared with the power consumed by recharging the load alone. In this case, the monitor need only monitor recharging of the power storage batteries. Once the power storage batteries are recharged, either to the end of first stage or the end of the second stage, the effector may stop operation of the generator or vehicle engine; recharging of the load may be completed using power from the power storage batteries, 64 , via electrical connection 66 . This configuration takes advantage not only of the greater match between the power output of the generator or vehicle engine and the power storage batteries, but also the great speed with which the power storage batteries may be recharged. Preferably, the power storage batteries are separate from, and in addition to any batteries present in the generator or vehicle, 52 .
[0036] FIG. 6 illustrate system or configuration, 70 , for efficient fuel consumption. Included in the figure is fuel containing generator or vehicle, 72 , a load, 82 , and one or more power storage batteries, 84 . Preferably, the load may be one or more lithium ion or nickel cadmium rechargeable batteries, optionally contained in or connected to one or more electronic devices. Preferably, the power storage batteries are lead acid batteries. Device, 76 , includes a monitor and an effector. Electrical connections, 74 and 80 , electrically connect the generator or vehicle to the load, and electrical connections 74 and 78 electrically connect the generator or vehicle to the power storage batteries; the device may also be electrically connected to the generator or vehicle, the load, and the power storage batteries, via the electrical connections, or may be sufficiently proximate to the electrical connections, for monitoring the current, voltage or power of the recharging operations. Electrical connection 80 is optional. In another configuration, such as when the monitor is monitoring the duration of the recharging operation, the device may be spaced away from the electrical connections. Another electrical connection, 86 , is present between the load and the power storage batteries. Also illustrated is a person, 88 , who is neither monitoring the recharging operation nor monitoring the device.
[0037] In the configuration of FIG. 6 , in contrast to the configuration of FIG. 4 , two recharging operations are taking place: recharging of the rechargeable batteries present in the load, 82 , and the rechargeable batteries present in the power storage batteries, 84 . The monitor present in the device, 76 , may monitor both recharging operations, or alternatively may only monitor the recharging of the power storage batteries, 84 . In operation, when the monitor within the device, 76 , determines that one or both recharging operations are nearing the end of the first stage, or entering or beginning the second stage, the effector will issue a sound, preferably louder than the generator or vehicle engine, for example louder than 47 to 59 dB, or send a message, such as a text message to a mobile telephone or a message to a pager carried by the person, to notify the person to turn off the generator or vehicle engine, thereby stopping the further consumption of fuel by the generator or vehicle, 72 . Alternatively but less preferably, when the monitor within the device, 76 , determines that one or both recharging operations are nearing the end of the second stage, or entering or beginning the third stage, the effector will issue a sound, preferably louder than the generator or vehicle engine, for example louder than 47 to 59 dB, or send a message, such as a text message to a mobile telephone, or a message to a pager, to notify the person to turn off the generator or vehicle engine, thereby stopping the further consumption of fuel by the generator or vehicle, 72 . Preferably, the effector within the device, 76 , does not use a visual signal such as a color change on a light emitting diode, emanating from the device, to notify the person. Preferably, the effector within the device, 76 , does not use a quite sound, for example having a loudness of less than 40 dB, to notify the person. The sound or signal from the device, 76 , is distinct from any sound or signal issued by the load, 82 , which indicates completion of recharging.
[0038] The greater efficiency noted for the configuration of FIG. 5 is also present in the configuration of FIG. 6 .
[0039] FIG. 7 illustrate system or configuration, 100 , for efficient fuel consumption. Included in the figure is a fuel containing generator, 102 , having a standard AC electrical outlet, 122 , and on-off switch, 124 . Also illustrated is a mobile telephone, 104 , containing rechargeable batteries, which acts as a load. Connected to the mobile telephone is an AC adapter cord, 106 , which has an AC plug, 110 , which converts AC current to DC current needed to recharge and operate the mobile telephone. A device for efficient fuel consumption, 108 , is also illustrated, which includes a housing, 116 , in which the monitor and effector are housed. The device also includes an electrical cable, 114 , having an AC outlet, 112 , which receives the AC plug, and is connected to the housing, which is electrically connected to an electrical cable have an AC plug, 118 , which plugs into the AC outlet of the generator. An electrical connection, 120 , is also part of the device, which electrically connects the effector to the on-off switch of the generator. In this aspect of the device, the monitor is an ammeter which monitors the current passing through the housing, 116 , from electrical cable, 118 , to electrical cable, 114 . When the monitor determines that the recharging operation of rechargeable batteries within the mobile telephone (which acts as the load in this configuration), have completed the first stage or second stage of recharging, then the effector sends a signal though electrical connection, 120 , which causes the generator on-off switch to stop the generator. In a further different configuration, the monitor is a timer set to a time corresponding to the amount of time for completing the first stage or second stage of recharging, then the effector sends a signal though electrical connection, 120 , which causes the generator on-off switch to stop the generator.
[0040] FIG. 8 illustrates externally visible parts of the device, 108 , in greater detail. In addition to those elements shown in FIG. 7 (including the electrical cables, 114 and 118 , the electrical connection, 120 , and the housing, 116 ), FIG. 8 also shows a display, 126 , for providing information to the user, such as in which stage of recharging the device will cause the recharging operation to end, and/or the type of batteries being recharges. Also shown are buttons, 130 and 132 , for selecting which type of batteries are to be recharged, and/or in which stage of recharging the device will cause the recharging operation to end. Lastly, button, 128 , may be used to turn the device on and off.
[0041] Optionally, button, 128 , may be used to mark the end-point of recharging or the end-point for a device completing a task. For example, a battery charging device, without the batteries or with fully charged batteries, may be connected to the device, 108 , while the generator, 102 , is running; the button, 128 , is then depressed to set the current or voltage which corresponds to the end-point of the recharging operation. In another example, a device which has completed a task, may be connected to the device, 108 , while the generator, 102 , is running; the button, 128 , is then depressed to set the current or voltage which corresponds to completion of the task.
[0042] FIG. 9 illustrate another system or configuration, 200 , for efficient fuel consumption. Included in the figure are a vehicle, 202 , having a diesel engine, and an electrical cable, 214 , which is plugged into the cigarette lighter (not shown) of the vehicle. The electrical cable has an AC outlet, 212 , into which is plugged an AC plug, 210 , which is connected to an AC adapter cord, 206 , which is in turn connected to a mobile telephone (which acts as the load), 204 , containing rechargeable batteries. Also illustrated is a device for efficient fuel consumption, 208 , which has a housing, 216 , and vehicle remote start-stop, 217 , for the vehicle, 202 . In the configuration illustrated in FIG. 9 , the device, 208 , does not include the electrical cable which electrically connects the vehicle to the mobile telephone. However, the device does include a monitor which includes an inductive ammeter; during operation the inductive ammeter is placed around and in proximity to the electrical cable, 214 , so that it can monitor the current flowing through the cable. The device also include an effector, which includes the vehicle remote start-stop, 217 : when the monitor determines that the recharging operation has completed the first stage, or has completed the second stage, it causes the effect to stop the diesel engine of the vehicle. In a further different configuration, the vehicle remote start-stop is replaced with a speaker for generating a loud sound; when the monitor determines that the recharging operation has completed the first or second stage, the speaking generates a loud sound sufficient to notify a person to turn off the engine of the vehicle.
[0043] The devices and systems described herein may be, or include, application specific integrated circuits (ASIC), electronic circuits, logic circuits, processors, computers, memory, wireless communication elements, internet connections and/or other suitable components that may execute one or more software and/or firmware programs, that provide the described functionality.
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A method for efficient fuel consumption comprises recharging batteries or operating a device carrying out a task, with an engine through an electrical connection. The method also includes monitoring at least one of (i) current in the electrical connection, (ii) voltage of the batteries, and (iii) length of time of the recharging or task, to determine if the recharging has reach a preselected endpoint or the task has been completed. The method further includes generating a signal through a communication link to cause the engine to stop operating by: (a) preventing operation of a spark plug, (b) preventing delivery of fuel to the engine, or (c) preventing delivery of oxygen to the engine.
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This is a continuation of application Ser. No. 476,776, filed Mar. 18, 1983, which was a continuation of application U.S. Ser. No. 289,167, filed Aug. 3, 1981.
BACKGROUND OF THE INVENTION
This invention relates generally to track-mounted, articulated overhead doors and particularly relates to an improved overhead door having an impact-resistant, knock-out bottom section.
Overhead doors having an articulated construction, such as those generally employed in garages, warehouses, or other enclosed structures, typically involve the use of a plurality of panels extending transversely across the door opening and arranged in a vertical linear array with adjacent edges of the panels flexibly coupled by means of hinges. This flexibility permits the door to be moved from a generally vertical orientation immediately adjacent the opening to an overhead horizontal position by means of a pair of parallel, curved tracks located on each side of the multi-sectioned door. The guide trackways generally include a vertical section which positions the door adjacent the opening, a horizontal section at the upper end of the vertical section that determines the open position of the door, and a curved section connecting the vertical and horizontal sections and over which the panels travel between the vertical and horizontal positions. The relative orientation of the door and the tracks is maintained by means of rollers coupled to the various sections of the door and positioned within and engaging the guide tracks. Each of the roller shafts is rigidly affixed to a section, or panel, of the door while the rotating portion of the roller which is mounted on the shaft engages the tracks, with its movement thereby constrained in guiding the door along the tracks.
While this type of door offers clear advantages in terms of ease of handling and storage in the open position, it has also suffered from various installation and operating limitations. The prior art discloses many approaches to solving design, construction and installation problems associated with these doors as evidenced by the following patents, and the improvements they represent, in this field: U.S. Pat. Nos. 2,907,383 to Kloote et al (plastic rollaway door for reduced weight and improved environmental durability); 2,938,578 to Stull (improved weather-tight door seal); 2,951,533 to Lucas et al (light-weight garage door assembly with interchangeable interlocking articulated sections); 3,023,804 to Howell (improved door lower seal and positioning means); 3,034,575 to Stroup (vertically acting door with improved seals); 3,090,427 to Stroup et al (upwardly acting door assembly with adjustable door jamb and sill seal positioning and locking means); 3,648,755 to Thiele (combination connecting cover/seal strip and hinge for inter-panel space of articulated doors); 3,654,730 to Fraleigh (flexible barrier extending across bottom portion of overhead door opening for intercepting debris); and 3,734,161 to Pierce (curtain-type overhead door with flexibly interlocking substantially flat panels which are rolled onto a barrel or drum).
Still another approach to a flexible partition for covering an opening is disclosed in U.S. Pat. No. 4,122,887 to Dussault et al which describes a pliant curtain closure supported by its upper edge and a portion of one side edge and which includes a window cut-out and attached weights to provide inertia when the closure is opened or when it is returned to its closed position.
Thus, it is readily apparent that the search for improvements in flexible, overhead doors has been rather extensive and intense. To date, however, the problem of damage to an overhead door caused by the impact of an object, such as a moving vehicle, with the door has not been addressed. An impact force applied to the lower section of the door when in the open or a partially closed position represents a constant potential source of damage thereto involving expensive repairs, temporary loss of the security and environmental protection provided by the door, and repair of the object, such as a forklift, automobile, or truck, impacting the overhead door. The present invention is directed to overcoming this problem and provides an improvement in articulated overhead doors which enhances their durability and safety.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved overhead door compatible with existing parallel track systems and to which existing doors may be easily adapted.
Briefly, the present invention contemplates a multi-section, hinged, overhead door attached by means of hinge-mounted rollers to parallel tracks. The bottom panel of the door is detachably mounted such that upon impact, with the door in a raised position, the bottom panel separates from the rollers, becoming detached from the fixed tracks and displaced by the impact force. Following the removal of the impact force, the resiliency of the bottom panel causes it to return to its original position between the vertical tracks to which it may again be semi-rigidly coupled by means of the rollers. The rigidity of the bottom panel with the door fully down and a bottom nosing seal in contact with the doorway's threshold provides security and an environmental barrier, while the upraised door affords increased safety and greater durability.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended claims set forth those novel features believed characteristic of the invention. However, the invention itself as well as further objects and advantages thereof, will best be understood by reference to the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings, where like reference characters identify like elements throughout the various figures, in which:
FIG. 1 is a side elevation view of the overhead, impact-resistant door of the present invention in the closed, or down, position;
FIG. 2 is a side elevation view of the overhead impact-resistant door in the fully raised position with the displacement of the flexible bottom panel shown in dotted line form;
FIG. 3 is a fragmentary inside view of an embodiment of the present invention with the door in the closed position;
FIG. 4 is an enlarged rear elevation view of part of FIG. 3 with parts broken away and shown in section;
FIG. 5 is a vertical section taken on line 5--5 of FIG. 4;
FIG. 6 is a fragmentary top plan view showing displacement of the door outwardly with respect to the door opening in accordance with the present invention; and
FIG. 7 is a fragmentary top plan view showing displacement of the door inwardly with respect to the door opening in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, there is shown an impact-resistant overhead door assembly 10 in accordance with the present invention in the closed, or down, and open positions, respectively. Overhead door 10 includes a plurality of panels, or sections, including a bottom panel 20, an upper panel 28 and a plurality of intermediate panels 22, 24 and 26 flexibly coupled together by means of hinges 30.
In the closed position overhead door 10 is positioned immediately adjacent to and in front of an opening 12 in a wall 14 with the bottom surface of opening 12 defined by a threshold 16. In the closed position overhead door 10 is oriented in a generally vertical direction while, as shown in FIG. 2, in the upraised, or open, position most of the panels of door 10 assume a horizontal position. Door 10 is moved between the open and closed position and is maintained or held in those positions by means of parallel tracks 18 located immediately adjacent the lateral portions of door 10. Tracks 18 include a curved portion 18a which couples the vertical and horizontal sections of parallel tracks 18. The present invention, of course, is not limited to a generally 90° turn in the parallel track configuration, but would work equally well with an entirely vertical track system where means are provided to hold the door in the open position, or any parallel track system where the door in the closed position is oriented between the vertical and horizontal configurations. The advantages in terms of closed door storage are obvious in the parallel track configuration shown in FIGS. 1 and 2.
FIG. 2 shows the overhead door 10 in the fully up position wherein bottom panel 20 extends below the upper surface of opening 12 defined by wall 14. In this configuration, and in any position of overhead door 10 intermediate between the full open and full closed positions, bottom panel 20 is subject to impact with objects moving, or being moved, through aperture 12. Upon impact with bottom panel 20, a moving object will cause the displacement of bottom panel 20 in either an outward or inward direction as shown by the dotted lines in FIG. 2. Heretofore, the imposition of an impact force of sufficient magnitude to so displace bottom panel 20 necessitated expensive and time-consuming repairs to or the replacement of bottom panel 20.
Referring to FIG. 3 and in accordance with the present invention, a bottom panel 20 is provided capable of absorbing high impact forces, being displaced rotationally thereby, and resuming its original position between and immediately adjacent parallel tracks 18 following the removal of the impact force.
The edge portions of the panels of overhead door 10 are linked together by means of edge hinges 31 while the central portions of the panels therebetween are coupled by means of inner hinges 30. Thus, bottom panel 20 is flexibly coupled to immediately adjacent panel 22 by means of edge hinges 31 and inner hinges 30. Bottom panel 20 is comprised of a plurality of vertical reinforcing members 32 and lower and upper horizontal reinforcing members 34, 36, oriented at approximately 90° with respect thereto. The vertical reinforcing members 32 are located adjacent where the edge and inner hinges 31, 30 are positioned on bottom panel 20 for structural integrity. Similarly, lower and upper horizontal reinforcing members 34, 36 extend the entire length of bottom panel 20 in providing enhanced reinforcement therefor. The hinges afford the flexibility required of overhead door 10 in traversing the curved portion 18a of the parallel tracks 18 while providing structural integrity for the multipanel configuration of overhead door 10. In addition, rollers 40 are rotationally coupled to edge hinges 31 which, in turn, are securely affixed to the lateral portions of each door panel. In this manner, the lateral edge portions of overhead door 10 are maintained in position relative to and guided by parallel tracks 18.
Referring to FIG. 4, there is shown an exploded and partially cutaway view of the lower left portion of the inside surface of overhead door 10 shown in FIG. 3. Attached to edge hinges 31 are rollers 40 which engage the immediately adjacent parallel track (not shown). Rollers 40 are detachably coupled to edge hinges 31 so that they may be removed therefrom by a force exerted on the roller in a direction generally parallel to roller shaft 40a. Thus, with rollers 40 engaging the immediately adjacent parallel track 18 in a conventional manner, the displacement of bottom panel 20 due to an impact force applied thereto will cause the edge portions of bottom panel 20 to be displaced away from the adjacent parallel track. This displacement of the edge portions of bottom panel 20 and the hinges rigidly affixed thereto will cause a separation between rollers 40, which are rotationally engaged by the adjacent parallel track 18, and the edge hinges 31. As flexible bottom panel 20 is distorted by an impact force, the bottom panel 20 flexes outward and, in doing so, causes the lateral end portions of the flexible panel 20 near the vertical reinforcing member 32 to fold inwards towards the center of the panel, withdrawing shaft 40 of hinge 31 from a shaft receiving surface in either rollers 40 or in the shaft receiving surface of hinge 31 mounted to the flexible panel 20. With the lateral edges of bottom panel 20 thus disengaged from parallel tracks 18, bottom panel 20 is free to move in response to the applied impact force and to "give" therewith. Thus, the displacement of bottom panel 20 in response to the applied force avoids the breaking, shattering or permanent distortion thereof in response to the applied force. A semi-rigid, flexible bottom nosing seal 48 is attached to the lower edge of bottom panel 20 and positioned in close contact with threshold 16 when overhead door 10 is in the closed position.
Referring to FIG. 5, there is shown a sectional view of bottom panel 20 taken along the plane 5--5 of FIG. 4. Bottom panel 20 is shown flexibly coupled to an intermediate panel 22 by means of an inner hinge 30. Immediately adjacent to inner hinge 30 and positioned between bottom panel 20 and intermediate panel 22 is a spacer groove 50 to accomodate the relative rotation of the immediately adjacent panels and more particularly the displacement of the upper right-hand portion 20a of bottom panel 20 relative to intermediate panel 22.
In a preferred embodiment of the present invention, bottom panel 20 includes an outer rubber surface 42 and an inner rubber surface 44 between which is provided a urethane filler 46. The combination of the two rubber strips separated by the filler material provides a semi-rigid structure capable of withstanding a high impact force. The interior structure of bottom panel 20 includes lower and upper horizontal reinforcing members 34, 36, each of which is in the form of a double box beam, preferably of molded rubber or of a rubberlike compound. Upper horizontal reinforcing member 36 is firmly affixed to outer and inner surfaces 42, 44, while a U-shaped bottom nosing seal 48 is positioned between the lower horizontal reinforcing member 34 and outer and inner surfaces 42, 44 of bottom panel 20. Vertical reinforcing members 32 are also formed from rubber or a rubber-like compound, while edge reinforcing members 38 in bottom panel 20 are preferably made from an extruded, light-weight metal, such as aluminum. The combination of the rigid edge reinforcing members 38 to which the flexible lower and upper reinforcing members 34, 36 are attached and the resilient vertical reinforcing members 32 afford bottom panel 20 the adaptability and durability required for carrying out the present invention.
In the cavity defined by outer and inner surfaces 42, 44 and lower and upper horizontal reinforcing members 34, 36 polyurethane foam is injected providing an impact-resistant structure for bottom panel 20. The structural integrity of bottom panel 20 to impact forces applied thereto is insured by the rectangular matrices of the vertical and horizontal reinforcing members. Bottom nosing seal 48 is preferably comprised of rubber, or a rubber-like compound, and affords impact flexibility and contact integrity between overhead door 10 and doorway threshold 16. With nosing seal 48 of a semi-rigid consistency and in firm contact with threshold 16 when overhead door 10 is in the closed position, bottom panel 20 may be displaced from its normal position intermediate between parallel tracks 18 only by a transverse force of very considerable magnitude applied thereto. Thus, for security and environmental reasons, overhead door 10 is positioned by means of nosing seal 48 in firm contact with door threshold 16 when in the down position to prevent the displacement of bottom panel 20 from its normal position spanning the lower portion of opening 12.
There has thus been shown an articulated, overhead door having a breakaway bottom panel which avoids costly repairs due to an impact force applied thereto when the door is open while providing security and an environmental barrier when the door is in the closed position.
While particular embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the invention in its broader aspects. The aim of the appended claims, therefore, is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A multi-section overhead door having an impact-proof bottom panel for improved safety and durability is disclosed. The door is displaced vertically along parallel tracks to which it is coupled by means of rollers. Impact with the bottom panel of the door when in a raised position results in the disengagement of the track rollers from the bottom panel and the displacement of the bottom panel from alignment with the tracks. With the impact force removed, the bottom panel resumes its original position between the tracks to which it can be remounted by conveniently repositioning the track rollers thereon. The bottom panel includes front and rear rubber surfaces with a urethane filler therebetween and a flexible bottom nosing seal.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to automatic recirculation valves and more particularly to recirculation valves having the ability to adjust the bypass recirculation flow to accommodate for various flow ranges.
BACKGROUND OF THE INVENTION
[0002] Automatic recirculation (ARC) valves are typically used in the oil and gas, power and chemical industries. In particular, ARC valves are used in connection with centrifugal pump applications to prevent pump overheating caused by the transfer of heat from a pump mechanism to the process fluid flowing through a system. During normal operation, this heat is transferred away from the pump and dissipated through the system via the process fluid. However, during periods of low process flow, the slower moving fluid does not dissipate the heat away from the pump sufficiently, thereby contributing to pump overheating. In addition, the vapor pressure increases as the temperature of the fluid within the pump increases, thereby increasing cavitation potential which damages the pump mechanism.
[0003] Recirculation valves are used to prevent this overheating by providing a path through which the pump maintains sufficient fluid flow during periods of low process flow through the system. Fluid enters a recirculation valve though a main inlet and exits the valve through a main outlet. The main valve element senses the rate of flow between the main inlet and outlet. A pressure differential across the main valve element causes the valve to open to permit process flow to the main outlet. When the main valve is open, a recirculation or bypass portion of the valve is closed which prevents the flow of fluid to an associated recirculation outlet. During times of low downstream demand, the differential pressure across the main valve is insufficient to open the valve. When the main valve is closed, the recirculation or bypass valve is open which allows for the flow of fluid through the recirculation chamber and consequently to the recirculation outlet.
[0004] A drawback associated with the above referenced ARC valve is that the capacity through the bypass valve is fixed depending on the application. For example, the bypass valve may be configured to accommodate a particular bypass Cv. Unfortunately, when ARC valves are installed in the field, the Cv rating may or may not be ideal for actual process conditions. Thus, field changes must be done manually to accommodate for the design differentials. The above-referenced drawbacks and others are overcome by the present invention described herein with reference to the detailed description, drawings and appended claims.
SUMMARY OF THE INVENTION
[0005] The present invention relates to an adjustable automatic recirculation valve having a main valve body, a main valve disk, a bypass valve and a dynamic adjustment assembly. The valve body includes a main inlet, a main outlet and a recirculating outlet. The main valve disk is positioned within the valve body opens in response to fluid flow between the main inlet and main outlet. A bypass valve, responsive to opening and closing of the main valve, controls the flow of fluid between the main inlet and the recirculating outlet. A dynamic adjustment assembly is housed within the valve body and is configured to control the operating lift associated with the maximum opening of the bypass valve to regulate fluid flow capacity to the recirculating outlet.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0006] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate an embodiment of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention.
[0007] FIG. 1 illustrates a cut-away perspective view of an ARC valve in a closed position according to an embodiment of the present invention.
[0008] FIG. 2 a - 2 c illustrates perspective views of individual members of adjustable recirculation assembly according to an embodiment of the present invention.
[0009] FIG. 3 illustrates a side cut-away view of an ARC valve according to an embodiment of the present invention.
[0010] FIG. 4 illustrates a cut-away perspective view of an ARC valve in an open position according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0011] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that the disclosure will be thorough and complete, and will convey the scope of the invention to those or ordinary skill in the art. In the drawings, like numbers refer to like elements.
[0012] FIG. 1 illustrates an exemplary embodiment of a recirculation main valve 10 in a closed position having housing sections 20 a and 20 b, a valve disk 30 enclosed within the housing 20 , a bypass or recirculation portion 40 and an adjustable recirculation assembly 100 . The housing sections may be connected using bolts 25 to form an internal cavity 35 through which fluid flows. Valve 10 has an inlet 50 located at one end of housing portion 20 a which is aligned with a downstream side of a centrifugal pump (not shown) for receiving process fluid. Flanged portion 21 a of housing section 20 a includes a plurality of mounting holes 22 a for mounting valve 10 to the downstream side of a process system. Valve 10 also includes an outlet 55 located at the other end of housing portion 20 b configured to provide process fluid away from valve 10 . Flanged portion 21 b of housing section 20 b includes a plurality of mounting holes 22 b for mounting valve 10 to the upstream side of a process system.
[0013] Disk 30 of the main valve is movably positioned along center shaft 31 which extends longitudinally from housing portions 20 a to 20 b. Disk 30 communicates with disk seat 29 which is positioned between housing portions 20 a and 20 b and provides a seal to prevent process from reverse flow between outlet 55 and inlet 50 . Seat 29 extends circumferentially around the outer perimeter of disk 30 . Shaft 31 is fixedly attached at a first end 31 a to the internal walls of housing portion 20 a via bracket 33 a which will be described in greater detail with reference to FIG. 2A . Likewise, shaft 31 is fixedly attached at a second end 31 b to the internal walls of housing portion 20 b via bracket 33 b. Brackets 33 a and 33 b are substantially perpendicular to the longitudinal axis of shaft 31 and are configured to withstand the forces associated with fluid flow through valve 10 . Bracket 33 b includes a circular base which is integrally formed with the interior wall of housing section 21 a and a mid-diameter beam similar to that disclosed in FIG. 2A adapted to receive an end 31 b of shaft 31 . However, bracket 33 b does not include the side portions 202 shown in FIG. 2A .
[0014] Sleeve 39 includes a annular internal recess 37 extending longitudinally from 36 A to 36 B. Recess 37 is configured to receive a bias spring 38 which, in its static position, exerts a force on disk 30 into a fully closed position such that disk 30 engages seat 29 to prevent reverse process flow through valve 10 . A shaft sleeve is connected to the disk 30 coaxial to the center of the disk. Sleeve 39 includes a threaded conical portion 41 which also extends around the lower side of disk 30 a radius distance from shaft 31 . Consistent with existing check valve functionality, when the differential pressure is sufficient, disk 30 is vertically displaced upward along shaft 31 toward outlet 55 against bias spring 38 . The vertical displacement of disk 31 breaks the seal with seat 29 causing process fluid to flow from inlet 50 through cavity 35 to outlet 55 .
[0015] Bypass or recirculation portion 40 generally includes a bypass valve 65 , body 60 , cavity 66 , recirculation port 52 , piston 80 and flanged portion 67 . A plurality of mounting holes 68 are spaced along flanged portion 67 for mounting recirculation portion 40 to bypass piping. Body 60 is integrally formed with valve housing section 20 a and cavity 66 is defined by the interior walls of body 60 . Piston 80 is movably positioned within cavity 66 and corresponds to the movement of valve disk 30 . Piston 80 engages bypass valve seat 65 b within cavity 66 to form a seal through which fluid can not flow. Piston 80 is positioned within cavity 66 and includes head portion 81 and a plurality of cascaded rings 82 . Piston 80 includes a central cylindrical passage 83 extending the length of piston 80 . The length of piston 80 , number of cascaded rings 82 depends on the recirculation pressure and flow needed for a particular application. For example, the number of cascaded rings 82 may be between 1 and 6 to accommodate Cv values typically from 0.2 to 75 and greater. In addition, the diameter of piston 80 is typically between about 1″ and 2.5″ and greater with cascaded rings 82 having the same diameter range. In this manner, a controlled multi stage pressure reducing bypass system is defined.
[0016] FIG. 2 a - 2 c illustrates perspective views of individual members of adjustable recirculation assembly 100 positioned within housing section 21 a and cavity 35 . Referring to FIG. 2 a, pivot support ring 200 includes ring support 201 , bracket 33 a, pivot supports 202 , and shaft retaining cavity 203 . The diameter of retaining cavity 203 is sufficient to receive shaft 31 . Ring support 201 has a diameter and circumference such that it is fixedly attached or integrally molded with the interior of housing section 21 a. Pivot supports 202 include retaining bores 202 a and 202 b which are adapted to receive and retain pivot arm 210 . FIG. 2 b illustrates pivot arm 210 which is positioned and retained by pivot support ring 200 . Pivot arm 210 includes extension arms 211 , base support beam 212 and lever support arms 213 . Extension arms 211 each include receiving portions 212 a and 212 b which connect to pivot supports 202 via retaining bores 202 a and 202 b. FIG. 2 c is a perspective view of pivot lever 204 which has a substantially horseshoe shape formed by walls 220 a, 220 b and 220 c and is positioned around shaft 31 . The front portion of pivot lever 204 is defined by angular lever member 221 . Slots 222 formed in inner walls 220 a and 220 c are adapted to receive actuator pin 230 (shown in FIG. 1 ). Turning briefly to FIG. 1 , as sleeve 39 traverses shaft 31 in an upward direction toward outlet port 55 caused by the differential pressure about disk 30 , sleeve 39 pulls assembly 100 upwards. This movement upwards causes pivot lever 204 to pivot about pivot pin 69 forcing lever 204 to rotate down toward intake 50 .
[0017] The functioning of assembly 100 and in particular lever 204 may be seen in FIG. 3 which is a side cut-away view of valve 10 with recirculation valve 65 in a open position. As can be seen, head 81 of piston 80 is positioned on angular lever member 221 . The position of head 81 on lever member 221 may be adjusted depending on the bypass recirculation valve opening required for a particular application. Thus, if head 81 is positioned higher on angular member 221 , i.e. toward end 221 a, head 81 will traverse the surface of angular member 221 from the point of contact toward end 221 a. Likewise, if head 81 was positioned lower on angular member 221 , towards end 221 b, head 81 will traverse the surface of angular member 221 a lesser distance and thereby force valve 65 to close a lesser distance D. Again, as sleeve 39 traverses shaft 31 in an upward direction toward outlet port 55 caused by the differential pressure about disk 30 , sleeve 39 pulls assembly 100 upwards and actuator pin 230 traverses within channel 231 of shaft 31 . This movement upwards causes pivot lever arm 210 to rotate downward and pivot lever 204 to pivot about pin new 69 .
[0018] FIG. 4 illustrates valve 10 in an open position whereby the seal between disk 30 and seat 29 is broken allowing process fluid to flow from inlet 50 to outlet 55 . As the sleeve 39 and disk 30 vertically traverse shaft 31 toward outlet 55 , bypass recirculation assembly 40 likewise moves in relation to shaft 31 as described above. This displacement causes angular member 221 to pivot in direction A. Because piston head 81 is in contact with a point along the surface of angular member 221 , the rotation of angular member 221 forces piston head 81 , and likewise piston 80 , to move toward recirculation outlet 52 within cavity 66 , thereby closing bypass valve 65 a distance D (as shown in FIG. 3 ).
[0019] An operator shaft 401 has a first end 401 a located at locking plate 402 near the outer surface of housing 20 a and extends to a second end 401 b for connection with pivot arm 210 . Locking plate 402 retains operator shaft 401 in position with housing 20 a. Operator shaft 401 is connected to pivot arm 210 which is connected to pivot lever 204 . As stated above, pivot lever 204 surrounds shaft 31 on at least three sides with a horseshoe shape and contacts head portion 81 via angular member 221 . The first end 401 a of operator shaft 401 includes an adjustment head 401 c used to adjust operator shaft 401 in receiving portion 212 a thereby changing the angle of pivot arm 211 and likewise changing the angle of pivot lever 204 . This change forces angular member 221 of pivot lever 204 to move thereby adjusting the point at which head 81 of piston 80 contacts angular member 221 . In particular, as operator shaft 401 is adjusted in direction A, pivot arm 211 is displaced downward in direction A which causes pivot lever 204 in direction A. The change in position of pivot lever 204 in direction A also moves angular member 221 and causes the point of contact with head 81 to move along the surface of angular member 221 in direction B. Likewise, if operator shaft 401 is adjusted in direction B, piston head 81 moves downward along the surface of angular member 221 in direction A. The movement of piston head 81 in directions A or B with respect to angular member 221 controls the opening and closing displacement of bypass valve 65 .
[0020] If the static relationship between piston head 81 and angular member 221 is changed either in direction A or B as described above, the distance piston 80 will travel within cavity 66 will change proportionally. Angular member 221 has an upper portion 221 a and a lower portion 221 b. By adjusting the static contact point of head 81 along the surface of angular member 221 toward either portions 221 a or 221 b, head 81 will be displaced based on this static (or starting) position. For example, if angular member 221 is adjusted such that head 81 has a static contact point closer to portion 221 a, head 81 has less surface area of angular member 221 to traverse. With less surface area of angular member 221 to traverse, shaft 80 will be displaced more within cavity 66 .
[0021] The displacement of shaft 80 within cavity 66 determines the open distance D of the bypass valve 65 . Likewise, if angular member 221 is adjusted such that head 81 has a static contact point closer to portion 221 b, head 81 has more surface area of angular member 221 to traverse, i.e. toward end 221 a. With more surface area of angular member 221 to traverse, piston 80 will be displaced a lesser distance within cavity 66 , thereby increasing the open distance D of bypass valve 65 . In other words, the distance which piston 80 travels (and consequently the distance D bypass valve 65 opens) depends on the static contact point between head 81 and angular member 221 . By adjusting the point at which head 81 contacts angular member 221 using operator pin 401 , an operator may field adjust the flow capability through bypass portion 40 of valve 10 quickly and easily.
[0022] In previous ARC valves, the bypass valve opening parameter D was factory set prior to shipment to a customer. However, if adjustments were needed during field installation, an installer had to remove the piston 80 , and update as to the needed adjustment parameters and reassemble the valve. The present invention avoids these issues by providing a bypass flow valve capable of easy field adjustability.
[0023] While the present invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims, and equivalents thereof.
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An adjustable automatic recirculation valve includes a valve body, a main valve disk, a bypass valve and a dynamic adjustment assembly. The main valve disk is positioned within the valve body and opens in response to fluid flow between a main inlet and a main outlet. The bypass valve controls the flow of fluid between the main inlet and the recirculating outlet. A dynamic adjustment assembly, housed within the valve body controls the operating lift associated with the maximum opening of the bypass valve to regulate fluid flow capacity to the recirculating outlet.
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FIELD OF THE INVENTION
This invention relates to a method for reducing friction during drilling operations and thereby reducing the horsepower requirements for rotary drilling operations. Specifically, this invention relates to the use of certain alloys as a hardface on the principal bearing surfaces of the drill string to reduce friction in rotary oil well drilling operations, especially directional drilling.
BACKGROUND OF THE INVENTION
In rotary drilling operations, a drill bit is attached to the end of a drill string which is rotated at the surface by a rotary table. The weight of the drill string causes the rotating bit to bore a hole in the earth. As the operation progresses, new sections of drill pipe are added to the drill string and increase its overall length. Periodically during the drilling operation, the open borehole is cased to stabilize the walls, and the drilling operation is resumed. As a result, the drill string usually operates both in the open borehole and within the casing which has been installed in the borehole.
The power to drill is transmitted through the drill string to the drill bit. The amount of power which can be transmitted is limited to the maximum torque a drill string can sustain.
During the drilling of a borehole through underground formations, the drill string undergoes considerable sliding contact with both the steel casing and rock formations. This sliding contact results primarily from the rotational and straight movements of the drill string in the borehole. Friction between the moving surface of the drill string and the stationary surfaces of the casing and formation creates considerable drag on the string and results in excessive torque during drilling operations. The problem caused by friction is inherent in any drilling operation, but it is especially troublesome in directionally drilled wells. Directional drilling is simply the intentional deviation of a wellbore from the vertical. In some cases the angle from the vertical may be as great as ninety degrees from the vertical. Such wells are commonly referred to as horizontal wells and may be drilled to a considerable depth and considerable distance from the drilling platform.
In all drilling operations, the drill string has a tendency to rest against the side of the borehole or the well casing, but this tendency is much greater in directionally drilled wells because of the effect of gravity. As the drill string increases in length or degree of vertical deflexion, the amount of friction created by the rotating drill string also increases. To overcome this increase in friction, additional power is required to rotate the drill string. In some cases, the friction between the drill string and the casing wall or borehole exceeds the maximum torque that can be tolerated by the drill string and drilling operations must cease. Consequently, the depth to which wells can be drilled using available directional drilling equipment and techniques is limited.
The most common methods for reducing the friction caused by the contact between the drill string and the well casing or borehole rely primarily on improving the lubricity of the drilling muds. It is generally agreed that bentonite helps reduce friction between the drill string and an open borehole. Diesel and other mineral oils are also often used as lubricants, but there is a problem with the disposal of the mud. Other additives include vegetable oils, asphalt, graphite, detergents and walnut hulls, but each has its own drawbacks.
One other common method for reducing the friction between the drill string and the well casing or borehole is to use aluminum drill string because aluminum is lighter than steel. However, the aluminum drill string is expensive, and it is not compatible with many types of drilling fluids (e.g. drilling fluids with high pH).
Still another problem encountered during drilling operations, especially directional drilling, is the wear on the casing and drill string that occurs when the metal surfaces contact each other. This abrasion between metal surfaces during the drilling of oil and gas wells results in excessive wear on both the drill string and the well casing. Presently, the preferred solution to reduce wear of drill strings is to hardface portions of the drill string. A tungsten carbide containing alloy, such as Stellite 6 and Stellite 12 (trademark of Cabot Corporation), has excellent wear resistance. Hardfacing protects the drill string, but it tends to cause excessive abrading of the well casing. This problem is especially severe during directional drilling because the drill string, which has a tendency to rest on the well casing, continually abrades the well casing as the drill string rotates. In addition, some of these hardfacing alloys, such as tungsten carbide, actually make the friction problem worse.
SUMMARY OF THE INVENTION
This invention is a method for reducing friction during drilling operations, especially directional drilling. This invention involves hardfacing at least part of the drill string with an alloy having the following composition: 50-65% Cobalt, 25-35% Molybdenum, 1-18% Chromium, 2-10% Silicon and less than 0.1% Carbon. Using this alloy to hardface a drill string will reduce the torque for drilling and allow the well to be drilled to a greater depth using conventional drilling equipment. In addition to reducing friction, the alloy used in this invention provides wear resistance for the drill string that is equal to or better than that obtained from alloys previously used in hardfacing drill pipe while reducing the wear on the well casing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is the discovery that friction between the drill string and the casing or rock can be reduced by hardfacing at least part of the drill string with an alloy having the following composition: 50-65% Cobalt, 25-35% Molybdenum, 1-18% Chromium, 2-10% Silicon and less than 0.1% Carbon.
The hardfacing must be applied to the principal bearing surface of the drill pipe over an area which is sufficient to provide adequate contact with the casing. The principal bearing surface is that part of the pipe having the largest diameter. In other words, the principal bearing surface is that part of the drill pipe which normally contacts the casing or rock. On a standard drill pipe the principle bearing surfaces are at the ends of the pipe joint.
Various techniques can be used to apply the hardface to the drill string components. At present, the two most commonly used methods are weld overlay and transfer plasma arc. Such techniques are commonly known to those skilled in the art. The preferred method for applying the hardface is the oxy-fuel method because it produces coatings with minimum defects. The coating should be applied to a thickness from about 0.010 inch to 0.5 inch, and preferably to a thickness from 0.125 inch to 0.250 inch.
While it is believed that any alloy having a composition within the specified range will function, the preferred alloys are Tribaloy 400 and Tribaloy 800 (trademark of Cabot Corp.) primarily because they are commercially available. Tribaloy 400 and 800 are Cobalt-Molybdenum based alloys having the following compositions, respectively: 62Co-28Mo-8Cr-2.6Si and 52Co-28Mo-17Cr-3.0Si. These preferred alloys have been suggested for use as hardfacing for various machine parts because they provide excellent wear resistance.
The preferred alloys and commonly used tungsten carbide containing alloys were tested for friction and wear properties. The tungsten carbide containing alloys were Stellite 6 and Stellite 12 which have the compositions 66Co-28Cr-4W-1.0C and 62Co-29Cr-8W-1.3C, respectively. The tests were performed using an alpha model LFW-1 testing machine according to the standard method for calibration and operation of the alpha model LFW-1 friction and wear testing machine, ANSI-ASTM D2714-68 (reapproved 1978).
Rotating rings were made of either AIS1 4137-H base steel or Type 304 SS surface coated with the various alloys, and stationary blocks were made from K55 casing steel. All of these materials are readily available. Friction tests were performed in 13 lbs. per gallon laboratory prepared fresh water drilling mud at 200 rpm and load of 200 lbs/inch. Wear testing was performed under the same conditions using 25,000 revolutions. Compositions of the coatings which were tested, and the test results are given in Tables 1 and 2.
TABLE 1______________________________________Effect of Surface Coatings on Friction CoefficientBetween Steel Ring and K-55 Casing Steel BlockSurface Coating Friction Percenton Ring Coefficient Improvement______________________________________None 0.22 --(A1S1 4137-H)Stellite 6 0.23 --(Type 304 SS)Stellite 12 0.22 --(Type 304 SS)Tribaloy 800 0.12 45(Type 304 SS)Tribaloy 400 0.12 45(Type 304 SS)______________________________________
TABLE 2______________________________________Effect of Surface Coatings on Wear betweenSteel Ring and K-55 Casing Steel Block* Block Ring Weight Percent Weight PercentSurface Coating Loss, Reduction in Loss, Reduction inOn Ring (mg) Block Wear (mg) Ring Wear______________________________________None 74.3 -- 119.0 --(A1S1 4137-H)Stellite 6 132.0 78 increase 32.0 67(Type 304 SS)Stellite 12 53.5 27 19.5 84(Type 304 SS)Tribaloy 800 15.3 79 11.3 90(Type 304 SS)Tribaloy 400 13.2 82 6.4 94(Type 304 SS)______________________________________ *Tests were carried out in 13 lbs. per gallon laboratory prepared fresh water drilling mud and loading conditions of 200 lbs/inch, at 200 rpm and 25,000 total revolutions.
Tests were also conducted using rings made of 4140 steel. In these tests, the preferred alloys were applied over an intermediate buttering layer of 309 SS or Inconel 600 using the oxy-fuel (OF) method and the transfer plasma arc (TPA) technique. Using an intermediate buttering layer is a common welding technique, and it serves to minimize cracking in the substrate and carbon pick-up by the overlay coating. For comparison purposes, tests were run on uncoated 4137-H steel and Type 304 SS steel coated by the tungsted inert gas (TIG) method. The friction and wear tests were performed under the same conditions as the previous tests, and the results are given in Tables 3and 4.
TABLE 3______________________________________Effect of Surface Coatings on Friction Coefficientbetween Steel Ring and K-65 Casing Steel Block Friction Percent Coeffi- Improve-Steel Ring/Buttering/Hardface/Procedure cient ment______________________________________4137-H/--/--/-- 0.24 --304SS/--/T-400/TIG 0.13 45304SS/--/T-800/TIG 0.12 504140/309/T-800/TPA 0.14 424140/309/T-800/OF 0.08 674140/309/T-400/OF 0.07 714140/Inconel/T-800/TPA 0.09 544140/Inconel/T-800/OF 0.07 714140/Inconel/T-400/OF 0.08 67______________________________________
TABLE 4__________________________________________________________________________Effect of Surface Coating onWear between Steel Ringand K-55 Casing Steel Block* Block Percent Percent Weight Reduction Ring Weight ReductionSteel Ring/Buttering/Hardface/Procedure Loss, (mg) in Block Wear Loss, (mg) in Ring Wear__________________________________________________________________________4137-H/--/--/ -- 144.5 -- 99.7 --304SS/--/T-400/TIG 15.3 89 33.5 66304SS/--/T-800/TIG 10.0 93 14.0 854140/309/T-800/TPA 36.0 75 33.8 664140/309/T-800/OF 37.5 74 30.5 694140/309/T-400/OF 53.5 63 36.8 634140/Inconel/T-800/TPA 30.7 78 71.3 284140/Inconel/T-800/OF 73.3 49 53.1 474140/Inconel/T-400/OF 48.0 66 55.6 44__________________________________________________________________________ *Tests were carried out in 13 lbs. per gallon laboratory prepared fresh water drilling mud and loading conditions of 200 lbs/inch, at 200 rpm and 25,000 total revolutions.
The alloys Tribaloy 400 and Tribaloy 800 were also applied to full-scale tool joints for actual field testing. Three tool joints were each coated with four bands of alloy approximately 7/8-inch wide. The alloys and methods of application were as follows:
309 stainless buttering layer, Tribaloy 400, oxy-fuel method (340F)
309 stainless buttering layer, Tribaloy 800, oxy-fuel method (380F)
Inconel 600 buttering layer, Tribaloy 800, transfer plasma arc technique (I8TP)
Each of the hardbanded tool joints was run for approximately 150,000 revolutions (20 hours at 125 rpm). The test fluid was a 16.0-ppg water-base mud with 0.5 percent sand added. The K-55 casing sample was loaded against the rotating tool joint with 2,000 pounds side load. Comparison tests were run using a regular tool joint.
As shown in Table 5, six tests were run. Each of the three hardbanded joints was run tested to about 150,000 revolutions. This was followed by a comparison run with a regular tool joint. To eliminate hydrodynamic lubrication, the majority of revolutions in the tool-joint test (4) were logged at 15 rpm. Consequently, that test lasted 120 hours. For the fifth test, a regular tool joint was machined to leave four raised bands of approximately the same geometry as on the hardbanded joints. This 4-band joint was run at 125 rpm for about 150,000 revolutions. It ran in the hydrodynamic mode and was allowed to continue. The final test was a repeat of test one using the 340F hardband.
TABLE 5______________________________________ (4) (5) (6) (1) (2) (3) Tool 4- 340F 340F 380F I8TP Joint Band Rerun______________________________________# of Revo- 145,000 150,000 147,000 158,000 146,000 146,000lutionsTotal Time 20.8 21.4 21.4 120.0 21.7 20.4(hrs)Final Casing .0717 .0909 .1096 .0720 .0917 .0871Wear (in.)Final Wear .488 .655 .791 1.176 .574 .647Volume (in..sup.3)Wear 0.98 1.16 1.49 2.03 1.72 1.37Coefficient(× 10.sup.-4)Avg. Frict. .225 .250 .242 .260 .159* .211Coef.(Running)15 rpm, .184 .204 .202 .276 .279 .2532000#Frict. Coef.______________________________________ *Due to majority of test being run in hydrodynamic mode.
The three hardbanded tool joints all demonstrated lower friction coefficients and lower wear coefficients than those measured with the regular tool joint. Combining tests of similar materials, the following general observations can be made:
______________________________________ Average WearMaterial Low rpm Fric. Coef. Coef. (× 10.sup.-4)______________________________________Tribaloy 400 0.22 1.18Tribaloy 800 0.20 1.33Tool-Joint Steel 0.28 1.88______________________________________
The Tribaloy 400 demonstrated 20 percent lower friction coefficient and 40 percent lower wear coefficient than steel, and the Tribaloy 800 demonstrated 30 percent lower friction coefficient and 30 percent lower wear coefficient than steel.
Another significant observation was the absence of a hydrodynamic effect with the Tribaloy coatings. None of the alloys ran in the hydrodynamic mode. The steel tool joint (4) was expected to run hydrodynamic based on previous test experience. The 4-band steel (5) was designed to determine if contact area was a factor in the observed hydrodynamic effect. The surprising result was that this reduced contact area tool joint also ran hydrodynamic at 125 rpm. Furthermore, both steel tool joints showed good agreement in low rpm friction . coefficients indicating no area effect. It is also interesting to note that the wear coefficient for both steel tests agree, indicating that the wear coefficient accurately accounts for contact area variations.
The foregoing description and embodiments are intended to illustrate the invention without limiting it thereby. It will be understood that various modifications can be made in the invention without departing from the spirit or scope thereof.
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Hardfacing the principal bearing surface of a drill pipe with an alloy having the composition of: 50-65% Cobalt, 25-35% Molybdenum, 1-18% Chromium, 2-10% Silicon and less than 0.1% Carbon reduces the friction between the drill string and the casing or rock. As a result, the torque needed for the rotary drilling operation, especially directional drilling, is decreased. The alloy also provides excellent wear resistance on the drill string while reducing the wear on the well casing.
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BACKGROUND OF THE INVENTION
This invention relates to a method for the excitation of long-lived fluorescent and phosphorescent dyes.
The publications and other materials used herein to illuminate the background of the invention, and in particular, cases to provide additional details respecting the practice, are incorporated by reference.
The method according to this invention allows the excitation of dyes emitting long-lived fluorescence and phosphorescence, with light of a wavelength considerably longer than their normal excitation wavelength. In the method according to the invention the dyes are excited by so-called two-photon excitation, the excitation resulting from the summation of the energies of two photons. The method according to this invention is applicable to fluorescent or phosphorescent dyes with an emission half-time longer than 100 ns due to an intermediary energetic triplet state. These dyes consequently have considerably longer half-times of excitation states than the emission half-times of ordinary organic dyes. The emission half-time of organic dyes is usually 1-10 ns, maximally 100 ns because emission usually does not occur via an intermediary triplet state.
These fluorescent and phosphorescent dyes are used in biospecific assays as molecular labels. Examples of the most widely used biospecific assay techniques are the immunoassay and the DNA hybridization assay. Binding of antibody is assayed by measuring the emitted light. Biospecific assays are used in in vitro diagnostics as well as in microscopy. In microscopy antibodies allow the detection and localization of e.g. the structural elements of micro-organisms.
Two-photon excitation of short-lived fluorescent molecules is a well-known technique e.g. in the fields of spectroscopy and microscopy. The said method requires, with current technology, high-energy laser instruments producing ultra-short pulses. Two-photon excitation is possible with a high momentary photon density. Simultaneous absorption of two photons is then probable. A high photon density is achieved by high luminous energy and by optical focusing of the light. Two-photon excitation has been described theoretically as early as 1931 (Goppert-Mayer, M. Ann. Phys. 1931, 9:273). The first prooves of the functionality of the method were obtained in the 1960's when laser instruments became available. In 1963 the first two-photon excitation in organic crystals was reported (Peticolas W. L., Goldsborough J. P., Reickhoff K. E. Phys. Rev. Let. 1963, Vol. 10/2). Two-photon excitations may also be observed with continuous high-energy laser radiation (Sepaniak M. J., Yeung ES. Anal. Chem. 1977, 49:1554-1556), but in this case the scattering of excitation light and heating of the sample interfere severely with measurement.
The advantage of two-photon excitation lies in the fact that visible light can be used for excitation instead of UV excitation. When visible light is used in order to elicit emission by exciting the dye by two simultaneous photon pulses, the scattering of light is reduced considerably as compared to excitation by UV radiation. In addition, two-photon excitation reduces damage caused by light to the sample below and above the object under examination. Two-photon excitation is best suited for the examination of small sample volumes or structures.
When applied to scanning microscopy, two-photon excitation allows a three-dimensional resolution comparable to the confocal microscope, without the second pinhole required in the confocal microscope. The method has been described in U.S. Pat. No. 5,034,613; 1991. The delimitation of the excitation in the three-dimensional space has been described in the literature (Anal. Chem. 1990, 62:973-976; Science, 1990, Vol. 248:73-76).
It is well known that the absorption of a single photon in a dye is, according to the concepts of probability, an independent event. The absorption of photons is a series of single, independent events. The probability of the absorption of a photon may be represented by a linear function. Absorption is linear as long as the energy states to be excited are not filled. It is known that the absorption of two or more photons is a nonlinear process (U.S. Pat. No. 5,034,613). When two or more photons are absorbed the absorption of single photons is no longer independent. A dye is excited only upon simultaneous absorption of all photons. The probability of the absorption of several photons is equal to the product of the probabilities of absorption of single photons. The emission caused by two photons is thus an exponential function to the power of two, the emission caused by three photons an exponential function to the power of three, etc.
The properties of an optical system for microimaging may be described by considering the response of the system to a point-like light source. A point-like light source forms, due to diffraction, an intensity distribution, characteristic of an optical system, in the focusing point (point response). This intensity distribution further reflects the resolution of the system. When normalized, this intensity distribution constitutes a probability distribution of the photons emitted from the point-like light source and hitting the focusing area. The nonlinear nature of two-photon absorption can be exploited to improve resolution. The probability distribution of two-photon excitation is then the normalized product of the intensity distributions of the first and the second photon. A probability distribution obtained in this way is clearly more delimited in the 3-dimensional space, especially in depth, than the probability ditribution of a single photon. Consequently, with two-photon excitation only the fluorescence generated in the clearly delimited, three-dimensional immediate vicinity of the focal point is detected (U.S. Pat. No. 5,034,613). The system is thus in its principle similar to the more traditional 3-dimensional optical microscope, or confocal microscope. In the confocal microscope the point response of the system is the normalized product of the probability distributions of point-like excitation and point-like detection (Confocal Microscopy, T. Wilson (ed), Academic Press, London, 1990, 1-64).
In order for the two photons to absorb, the dye must absorb the photons in such a way that the total sum of the energies of the photons equals the energy required for excitation (FIG. 1). The excitation then proceeds either via the intermediary energy state (omega 1) of the electrons of the molecule or directly to the excitation state (omega 2). The different possibilities of double-photon excitation are displayed in FIGS. 1A and 1B: in Figure A, directly as the combined result of two photons (lambda 1 and lambda 2); in Figure B, via the intermediary energy state (omega 1). Excitation via an intermediary state (FIG. 1B) requires a dye having such an intermediary energy state. Direct excitation of two photons according to FIG. 1A requires no intermediary state, instead the photons must absorb simultaneously, within approximately 10 -15 seconds, in the same chromophor of the dye.
A disadvantage of current systems based on two-photon excitation is the cost of the extremely high-power pulsed laser and the large size and complexity of the equipment. A continuous laser requires continuous power of several watts. This destroys nearly all known organic samples. A further disadvantage is the scant amount of emitted light compared to excitation light, and scattering of excitation light in addition interferes with the detection of the emission from ordinary short-lived dyes.
The excitation states of excited dyes discharge their energy in an exponential relation according to equation [1]:
N=N.sub.0 exp(-t/tau) [1]
N is the number of discharging molecules at a given time point, N 0 is the number of molecules discharging at time point=0, and tau is the average life-time of the excitation states ("decay parameter"). In the following discussion the terms long-lived and short-lived dyes are used to designate dyes with a long (100 ns-10 ms) or a short (1 ns-100 ns) average life-time tau.
Time-resolved detection of long-lived dyes involves the use of pulsed light for the excitation of the dye, and detection is started after a delay with respect to the excitation pulse. Detection is typically by photon counting, the counting being done within a specified time window. When detecting lanthanide chelates the photons are counted within e.g. 0.1-1 ms after the termination of the excitation pulse.
It is well known that time-resolved fluorescence detection of long-lived fluorescent dyes allows a sensitivity greater by several orders of magnitude than is possible in the detection of short-lived fluorescent molecules. The said molecules have allowed e.g. partial replacement of radioisotopes in immunodiagnostics and improvement of the sensitivity of detection (Soini, Lovgren. CRC Crit. Rev. Anal. Chem. 1987, 18:105-154).
Also in microscopy time-resolved detection of long-lived fluorescence allows reduction of background and thus greater sensitivity (Seveus et al. Cytometry, 1990, 13:329-338).
Long-lived fluorescence required in time-resolved detection is a property of e.g. the ions Eu 3+ , Sm 3+ , and Tb 3+ of the lanthanide group. In inorganic compounds, the absorption properties of these metals are quite inferior, but when an organic ligand is linked to the metal, absorption can be improved considerably. In these so-called lanthanide chelates the photon to be excited is absorbed in the organic ligand, from which the excitation energy is transferred to the lanthanide ion. The excitation of all known lanthanides occurs in UV area 250 nm-370 nm. The structure and use of lanthanide chelates has been described by e.g. Ilkka Hemmila in his book: Applications of Fluorescence in Immunoassays: 7.4.1 (140-145), John Wiley & Sons, N.Y., 1991.
A known disadvantage of UV-excited long-lived dyes like the lanthanide chelates is the scattering of light in the UV area, which interferes with the detection of emission. Also the manufacturing of UV-transparent components functioning correctly with UV light is difficult. Neither is the functioning and stability of the flashlamps currently used in immunoassays satisfactory in all respects. Consequently, it will be advantageous to design a system capable of employing excitation light of longer wavelength.
When ultrashort pulses (<1 ps) described in U.S. Pat. No. 5,034,613 are used for two-photon excitation, the life-time of the dye is without significance because the life-time of the short-lived or long-lived light-emitting dyes is in any case longer by orders of magnitude than the life-time of the exciting pulse. During the ultrashort pulse the energy states will be excited independently of the life-time of the emission of the dye. Ultrashort pulses are advantageous when using short-lived fluorescent molecules, as they allow control of average energy and damage to the sample. The scattering of light detected by the measuring instruments is also the least with ultrashort pulses. The dependence of the fluorescence intensity (I) obtained with two-photon excitation, on the excitation mechanism may be modelled by the equation:
I=Constant*P.sup.2 t [2]
P is the maximum power of the pulsed excitation light, and t is the duration of the pulse. The constant is dependent on the optical system and the dye used. This principle has been described in the literature (Wirth, Fatumbi. Anal. Chem. 1990, 62:973-976). This principle can also be deduced by the methods of probability calculation.
In two-photon excitation of short-lived molecules the objective is to achieve as short pulses as possible, of maximal power, to keep the energy of the pulses according to equation [2] as low as possible.
BRIEF SUMMARY OF THE INVENTION
The characteristics of the invention are shown in claim 1.
In the method according to this invention the objective is to realize two-photon excitation without course to the use of ultrashort laser pulses. The essence of this invention lies in the observation that the emission generated from two-photon excitation of long-lived fluorescent and phosphorescent dyes can be detected by time-resolved methodology without interference from the scattering of the excitation light. The long life-time of the fluorescence or phosphorescence also allows the use of longer excitation pulses and correspondingly lower excitation power. In the linear single-photon excitation the use of pulsed light allows straight-forward reduction of the peak power of the pulse, the peak power of the pulse being inversely related to the duration of the pulse. In two-photon excitation the peak power of the pulse can be reduced so that the peak power of the pulse according to equation [2] in this case is inversely related to the square root of the duration of the pulse.
In two-photon excitation time-resolved detection is performed in the same way as in normal time-resolved detection. A long-lived dye is excited via double-photon absorption with a pulse shorter or at the most as long as the life-time of the dye in question, in the case of lanthanide chelates (tau=1 ms) e.g. 0.1-1 ms). The start of detection is delayed as in normal time-resolved detection, and the measurement is performed in a time-window appropriate to the dye used.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in the following section by reference to the adjoining illustrations in which
FIGS. 1A and 1B illustrate schematically the principles of two-photon excitation
FIG. 2 represents the instrument constructed according to the invention for the testing of the method
FIG. 3 displays the measurement function obtained with the method according to the invention, which function allows the demonstration of the applicability of the invention
FIG. 4 gives an example of the application to immunoassay of the method according to the invention
FIG. 5 gives an example of the application to microscopy of the method according to the invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The mathematical modelling of the principle of this invention is best performed by applying equation [2] in another form:
P.sub.1.sup.2 t.sub.1 =P.sub.2.sup.2 t.sub.2 [ 3]
The two sides of the equation [3] describe the relation of the peak powers of the two pulses (pulse 1 and pulse 2) to the duration of the pulses, under the assumption of unaltered number of two-photon excitation events. An example in U.S. Pat. No. 5,034,613 describes the two-photon excitation of a short-lived dye (life-time<10 ns). In the example an average power of 50 mW, pulse duration of 100 fs and repetition frequency of 80 MHz were calculated. The peak power then is 6.2 kW. The theoretical calculation has been verified by actual measurement to be of the correct order of magnitude. In the method according to this invention the assumption may be made that the absorption parameters of a long-lived dye are the same as in the example of the U.S. Pat. No. 5,034,613, and according to equation [3] a pulse with a power of 200 mW and a duration of 0.1 ms allows the attainment of the same intensity of two-photon fluorescence than a pulse with a power of 6.2 kW and a duration of 100 fs. In the fluorescence detection of short-lived dyes this kind of consideration is merely theoretical, because with dye life-times of the order of a few nanoseconds the duration of the excitation pulses could be at the most of the same order to allow identification of the photons generated in fluorescence, as distinct from the excitation pulse. Time-resolved detection of a dye with a half-life of 1 ms allows an excitation pulse of 0.1 ms in order to avoid any significant interference by the duration of the pulse with the time-resolved detection of two-photon fluorescence. The said methodology thus allows two-photon excitation of long-lived dyes with low pulse peak power. The sensitivity, higher by several orders of magnitude, attainable with time-resolved detection allows the reduction of the peak power of the excitation pulse. The method according to this invention consequently allows the detection of two-photon-excited long-lived fluorescence or phosphorescence with a power of the excitation pulse of a few milliwatts. In practice the duration of the pulse to be used can be optimized according to a specified peak power. When the duration of the pulse approaches the half-time of the emission from the dye used equation [2] is no longer valid because during excitation a proportion of the excitation states discharge according to equation [1]. When the energy states of the dye are not filled the optimal duration of the pulse is usually of the same order than the half-time of the emission from the dye. With longer duration of the pulse the energy transferred to the sample also increases, in which case care must be taken not to damage the sample. If needed, shorter duration of pulse or lower repetition frequency of excitation pulses is selected.
For the testing of the operation of the method according to this invention measuring instrumentation was constructed as illustrated in FIG. 2. The sample used was a crystal of yttrium oxysulphide activated with europium (Y 2 O 2 S 2 :Eu 3+ ), whose emission half-time is approximately 0.7 ms and the wavelength of maximum absorption approximately 300 nm. The light source L1 was an argon-krypton mixed gas laser used at the wavelength of 647 nm. The excitation light was converged with lens O1 onto revolving shutter C1 and further diverged to make it parallel, with lens O2. The monochromatic quality of the excitation light was assured with excitation filter F1. Beam divider M1 divided the light of the excitation pulse between power monitor P and the object to be excited N. The division ratio at the wavelength used was about 15% to the power monitor and about 85% to the object to be excited. Beam divider M1 is made of quartz and thus emits no interfering long-lived fluorescence of its own. Microscope objective O3 was used to focus the beam of light onto sample crystal N. The emission from the sample was returned via objective O3 to beam divider M1. M1 deflected 15% of the emitted light to the direction of detector I1. To reduce diffused light the emitted light was focused onto aperture A1 with lens O4. Emission filter F2 was placed in front of the aperture. The bandpass of the emission filter is 616 nm±8 nm. Photon counting with photomultiplier I1 was used for detection, and counting was restricted to a time window of 200 μs-1 ms after the termination of the excitation pulse. A constant number of pulses and counts were repeated until the signal could be distinguished from background with sufficient efficacy. Excitation intensity was modified for the testing of the two-photon excitation. FIG. 3 illustrates the detection of the emission from a crystal of Y 2 O 2 S 2 :Eu 3+ . The x-axis represents excitation intensity (I exc ) and the y-axis the fluorescence signal emitted (I em ), respectively. The maximum peak power of excitation in the sample was in this case lower than 5 mW. The detection was repeated with several crystals. The repeated detection results were similar within the margin of error. The result displayed in FIG. 3 shows the nonlinear relation of the emission to excitation intensity. FIG. 3 allows description by equation [2] within the limits of the margin of error and the background in the detection.
To summarize, it may be stated that the method according to this invention allows e.g. the two-photon excitation of lanthanide chelates with a low-power light source, when fluorescence is detected with time-resolved methodology. As excitation is performed with visible light and a pulse with low peak power the instrument is economic and easy to use. The said invention further allows the use of lanthanide chelates having an excitation maximum in the region of 270 nm-330 nm. This short-wavelength UV region presented formerly little possibility for exploitation because conventional optic materials and components do not function in this wavelength region.
The method according to the invention can be used in biospecific assays by replacing UV excitation formerly required by fluorescent or phosphorescent dyes by excitation with visible light, the excitation in this case being based on two-photon excitation. The pulse power required being low, in practice, the cost of the instrumentation can be contained.
In biospecific assays the method according to the invention further allows the delimitation of the size of the area to be excited and consequently the reduction of background fluorescence which interferes with detection. The accuracy and sensitivity of the detection can thus be improved.
In microscopy, the method according to the invention further extends the applicability of long-lived fluorescent and phosphorescent dyes. With a scanning microscope 3-dimensional resolution can be attained without resorting to a complex instrumentation, and the imaging properties of the microscope can be improved by performing the imaging process in the best spectral area of current microscope optics. In addition, damage caused to the sample by light is reduced, as use of UV light can be avoided.
The method according to the invention can also be used in other types of time-resolved detection systems where the nonlinear two-photon procedure may present advantages.
The method according to the invention can be extended to include excitation by three or several photons. The required peak power will then be higher but the sensitivity of time-resolved detection still allows use of modest intensities. It should be noted that the term "two-photon excitation" employed in this patent application shall be understood to designate multi-photon excitation in general, two-photon excitation being the most widely used method and the easiest to realize.
The method according to the invention can also be used with long-lived dyes other than lanthanide chelates. Examples of such dyes are phosphorescent metalloporphyrins or fluorescent cryptates.
As the powers required in the method according to the invention are low with long pulse duration, other light sources are possible in addition to lasers. Other light sources could be e.g. high-power xenon discharge lamps. When using a xenon discharge lamp, a specified spectral band, instead of one wavelength, can be employed for excitation, corresponding to the absorption band of the two-photon excitation of the dye.
In the method according to the invention the laser instrument may be e.g. an air-cooled continuous krypton ion laser whose krypton band of 647 nm can be used to excite a 323.5 nm state by two-photon excitation. Semiconductor lasers for the region 600 nm-1300 nm are also currently available, whose energy is sufficient for two-photon excitation of long-lived dyes.
In biospecific assays the method according to the invention can be exploited e.g. in an instrument like the fluorometer illustrated in FIG. 4. Light source L1 and light source L2 are converged with dichroic mirror (beam divider) M1 to form a light pencil. The light sources L1 and L2 should preferably be point-like, which allows the maintenance of their peak power at a low level. L2 and M1 may be omitted if desired, as two-photon excitation can be performed with just one light source. The light pencil is chopped with optic chopper C1 to generate the pulse required for time-resolved detection. When a pulsed light source is used C1 may be omitted. The pulse-shaped light pencil is focused with lens O1 onto sample N. The long-lived emission light is returned via lens O1 and resolved with dichroic mirror M2 and emission filter F1 from the wavelength of the excitation light. The time-resolved detection is performed with detector I1, delaying detection until the background signal is sufficiently low. Detector I1 may be e.g. a photomultiplier tube or any other photodetector. This description of the instrument shall be understood to be given as an example only.
In microscopy, the method according to the invention may be exploited by an instrument according to FIG. 4 in its principle, in which instrument lens O1 is replaced by an objective suitable for microscopy, and sample N is replaced by a microscopic sample, respectively. Light sources L1 and L2 must be point-like also in this case. In order to form an image, either the sample A1 must be moved after detection of each point or the beam must be deflected. The structure of a scanning microscope has been described e.g. in Confocal Microscopy, T. Wilson (ed.), Academic Press, London, 1990 (1-64). The image is formed with an instrument, e.g. a computer registering detected signals.
An excellent way of exploiting semiconductor technology and the method according to this invention has been described in FIG. 5. The point-like light source has been replaced with a beam-like light source. This light source may be e.g. a semiconductor laser array or matrix. Other light sources, which are focused onto a narrow slit with e.g. a cylindrical lens, may also be used. The semiconductor laser is, however, the most economical to use, because the power required may be increased simply by increasing the number of the light-producing elements. In the system according to FIG. 5 the pulsed beam-like light source L1 is deflected with mirror M1 and focused with objective O1 to generate a beam-like excitation band in sample N1. If a matrical light source is used, deflection is unnecessary. The emission light is resolved from the excitation light with dichroic mirror M2 and focused onto the surface of a CCD element via emission filter F1 and shutter S1. Deflection of the excitation band results in a different storage site of the emission on the surface of the CCD element. The entire image area generated when the excitation band is deflected across the image area is integrated in the CCD element. In the time-resolved methodology the light hitting the CCD element is chopped with shutter S1. S1 may be operated mechanically or electrically. The said instrument corresponds in some of its constituents to the bilateral confocal microscope described in literature (Brakenhoff, Visscher. J. Microsc. 1992, 165:139-146). In the bilateral confocal microscope pinholes are replaced with a narrow slit, and scanning is performed in a bilateral manner with one mirror, the front side of the mirror deflecting the exciting narrow slit in the sample and the back side of the mirror deflecting the detection slit on the CCD element. In the system described in FIG. 5 the bilateral scanning using the two sides of the same mirror is unnecessary, due to the nonlinear excitation process, which makes the instrument simpler, allowing a greater amount of emission light to be detected.
The examples for microscopy shall be understood to represent examples only. The method according to the invention may be exploited also in other systems applicable to microscopy.
It will be appreciated that the methods of the present invention can be incorporated in the form of a variety of embodiments, only a few of which are disclosed herein. It will be apparent for the artisan that other embodiments exist and do not depart from the spirit of the invention. Thus, the described embodiments are illustrative and should not be construed as restrictive.
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A method for the two-photon excitation of long-lived fluorescent or phosphorescent dyes with long low-power pulses. In the method time-resolved detection is used to detect long-lived dyes. In the method long-lived dyes are excited to the excited state with light pulses of long duration via double-photon absorption. In the two-photon absorption process the chromophor of the dye molecule is excited through the summation of the energies of two or more photons when they are simultaneously absorbed. As the method is based on the use of pulses of long duration and on time-resolved detection the peak power of the pulses may be kept low. Long pulses of low power can be produced with a great variety of low-power light sources. The light source may in this case be e.g. a semiconductor laser. The excitation technique according to the invention may exploit the doubling or multiplication of the excitation wavelength or the nonlinearity of the two-photon absorption process. The method may be used for the detection of the fluorescence or phosphorescence from long-lived dyes for the determination of biospecific binding in applications of analytical or microscopic methods.
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The instant application is a continuation of U.S. Ser. No. 10/110,397 filed Apr. 12, 2002 now U.S. Pat. No. 6,544,993, which is a 371 of PCT/EP00/10445 filed Oct. 24, 2000, which claims the benefit of U.S. Provisional application 60/203,950 filed May 12, 2000.
FIELD OF APPLICATION OF THE INVENTION
The invention relates to novel tetrahydrothiopyran-derivatives, which are used in the pharmaceutical industry for the production of medicaments.
KNOWN TECHNICAL BACKGROUND
International Patent Applications WO98/31674, WO99/31071, WO99/31090 and WO99/47505 disclose phthalazinone derivatives having selective PDE4 inhibitory properties. In the International Patent Application WO94/12461 and in the European Patent Application EP 0 763 534 3-aryl-pyridazin-6-one and arylalkyl-diazinone derivatives are described as selective PDE4 inhibitors.
DESCRIPTION OF THE INVENTION
It has now been found that the tetrahydrothiopyran-derivatives, which are described in greater details below, have surprising and particularly advantageous properties.
The invention thus relates to compounds of formula I
in which
R1 and R2 are both hydrogen or together form an additional bond, A represents S (sulfur), S(O) (sulfoxide) or S(O) 2 (sulfone), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 is halogen, 1-4C-alkoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R4 is halogen, 1-8C-alkoxy, 3-7C-cycloalkoxy, 3-7C-cycloalkylmethoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R5 is halogen, 1-4C-alkoxy, 3-5C-cycloalkoxy, 3-5C-cycloalkylmethoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R6 is 1-4C-alkyl and R7 is hydrogen or 1-4C-alkyl,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked 5-, 6- or 7-membered hydrocarbon ring, optionally interrupted by an oxygen or sulphur atom, and the salts of these compounds, with the proviso, that those compounds of formula I are excluded, in which A represents S (sulfur) and Ar represents a benzene derivative of formula (a) and both of R3 and R4 are other than halogen.
1-4C-Alkyl is a straight-chain or branched alkyl radical having 1 to 4 carbon atoms. Examples are the butyl, isobutyl, sec-butyl, tert-butyl, propyl, isopropyl, ethyl and methyl radicals.
1-4C-Alkoxy is a radical which, in addition to the oxygen atom, contains a straight-chain or branched alkyl radical having 1 to 4 carbon atoms. Alkoxy radicals having 1 to 4 carbon atoms which may be mentioned in this context are, for example, the butoxy, isobutoxy, sec-butoxy, tert-butoxy, propoxy, iso-propxy, ethoxy and methoxy radicals.
1-8C-Alkoxy is a radical which, in addition to the oxygen atom, contains a straight-chain or branched alkyl radical having 1 to 8 carbon atoms. Alkoxy radicals having 1 to 8 carbon atoms which may be mentioned in this context are, for example, the octyloxy, heptyloxy, isoheptyloxy (5-methylhexyloxy), hexyloxy, isohexyloxy (4-methylpentyloxy), neohexyloxy (3,3-dimethylbutoxy), pentyloxy, isopentyloxy (3-methylbutoxy), neopentyloxy (2,2-dimethylpropoxy), butoxy, isobutoxy, sec-butoxy, tert-butoxy, propoxy, isopropoxy, ethoxy and methoxy radicals.
Halogen within the meaning of the present invention is bromine, chlorine and fluorine.
3-7C-Cycloalkoxy stands for cyclopropyloxy, cyclobutyloxy, cyclopentyloxy, cyclohexyloxy or cycloheptyloxy, of which cyclopropyloxy, cyclobutyloxy and cyclopentyloxy are preferred.
3-7C-Cycloalkylmethoxy stands for cyclopropylmethoxy, cyclobutylmethoxy, cyclopentylmethoxy, cyclohexylmethoxy or cycloheptylmethoxy, of which cyclopropylmethoxy, cyclobutylmethoxy and cyclopentylmethoxy are preferred.
3-5C-Cycloalkoxy stands for cyclopropyloxy, cyclobutyloxy and cyclopentyloxy.
3-5C-Cycloalkylmethoxy stands for cyclopropylmethoxy, cyclobutylmethoxy and cyclopentylmethoxy.
1-4C-Alkoxy which is completely or predominantly substituted by fluorine is, for example, the 2,2,3,3,3-pentafluoropropoxy, the perfluoroethoxy, the 1,2,2-trifluoroethoxy and in particular the 1,1,2,2-tetrafluoroethoxy, the 2,2,2-trifluoroethoxy, the trifluoromethoxy and the difluoromethoxy radical, of which the difluoromethoxy radical is preferred. “Predominantly” in this connection means that more than half of the hydrogen atoms of the 1-4C-alkoxy group are replaced by fluorine atoms.
As spiro-linked 5-, 6- or 7-membered hydrocarbon rings, optionally interrupted by an oxygen or sulphur atom, may be mentioned the cyclopentane, cyclohexane, cycloheptane, tetrahydrofuran, tetrahydropyran and the tetrahydrothiophen ring.
Suitable salts for compounds of the formula I are all acid addition salts. Particular mention may be made of the pharmacologically tolerable inorganic and organic acids customarily used in pharmacy. Those suitable are water-soluble and water-insoluble acid addition salts with acids such as, for example, hydrochloric acid, hydrobromic acid, phosphoric acid, nitric acid, sulphuric acid, acetic acid, citric acid, D-gluconic acid, benzoic acid, 2-(4-hydroxybenzoyl)benzoic acid, butyric acid, sulphosalicylic acid, maleic acid, lauric acid, malic acid, fumaric acid, succinic acid, oxalic acid, tartaric acid, embonic acid, stearic acid, toluenesulphonic acid, methanesulfonic acid or 3-hydroxy-2-naphthoic acid, the acids being employed in salt preparation—depending on whether a mono- or polybasic acid is concerned and depending on which salt is desired—in an equimolar quantitative ratio or one differing therefrom.
Pharmacologically intolerable salts, which can be obtained, for example, as process products during the preparation of the compounds according to the invention on an industrial scale, are converted into pharmacologically tolerable salts by processes known to the person skilled in the art.
According to expert's knowledge the compounds of the invention as well as their salts may contain, e.g. when isolated in crystalline form, varying amounts of solvents. Included within the scope of the invention are therefore all solvates and in particular all hydrates of the compounds of formula I as well as all solvates and in particular all hydrates of the salts of the compounds of formula I.
One embodiment (embodiment 1) of the invention are compounds of formula I in which
R1 and R2 are both hydrogen or together form an additional bond, A represents S(O) (sulfoxide) or S(O) 2 (sulfone), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 is halogen, 1-4C-alkoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R4 is halogen, 1-4C-alkoxy, 3-5C-cycloalkoxy, 3-5C-cycloalkylmethoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R5 is halogen, 1-4C-alkoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R6 is 1-4C-alkyl and R7 is hydrogen or 1-4C-alkyl,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane, cyclohexane, tetrahydrofuran or tetrahydropyran ring, and the salts of these compounds.
Compounds of formula I of embodiment 1 which are to be emphasized are those in which
R1 and R2 together form an additional bond, A represents S(O) (sulfoxide) or S(O) 2 (sulfone), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 is 1-2C-alkoxy, or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R4 is halogen, 1-4C-alkoxy or 3-5C-cycloalkoxy, R5 is 1-2C-alkoxy, or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R6 is methyl, R7 is hydrogen,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane or cyclohexane ring, and the salts of these compounds.
Compounds of formula I of embodiment 1 which are particularly to be emphasized are those in which
R1 and R2 together form an additional bond, A represents S(O) (sulfoxide) or S(O) 2 (sulfone), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 is methoxy or ethoxy, R4 is chlorine, methoxy, ethoxy or cyclopentyloxy, R5 is methoxy, R6 is methyl, R7 is hydrogen,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane or cyclohexane ring, and the salts of these compounds.
A further embodiment (embodiment 2) of the invention are compounds of formula I in which
R1 and R2 together form an additional bond, A represents S(O) (sulfoxide) or S(O) 2 (sulfone), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 is 1-2C-alkoxy, or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R4 is 1-4C-alkoxy, R5 is 1-2C-alkoxy, or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R6 is methyl, R7 is hydrogen,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane or cyclohexane ring, and the salts of these compounds.
Compounds of formula I of embodiment 2 which are to be emphasized are those in which
R1 and R2 together form an additional bond, A represents S(O) (sulfoxide) or S(O) 2 (sulfone), Ar represents a benzene derivative of formula (a)
wherein
R3 is methoxy, R4 is methoxy, and the salts of these compounds.
A further embodiment (embodiment 3) of the invention are compounds of formula I in which
R1 and R2are both hydrogen or together form an additional bond, A represents S (sulfur), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 1-4C-alkoxy, or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R4 is halogen, R5 is halogen, 1-4C-alkoxy or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R6 is 1-4C-alkyl and R7 is hydrogen or 1-4C-alkyl,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane, cyclohexane, tetrahydrofuran or tetrahydropyran ring, and the salts of these compounds.
Compounds of formula I of embodiment 3 which are to be emphasized are those in which
R1 and R2 together form an additional bond, A represents S (sulfur), Ar represents a benzene derivative of formula (a) or (b)
wherein
R3 is 1-2C-alkoxy or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R4 is chlorine, R5 is 1-2C-alkoxy or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R6 is methyl R7 is hydrogen,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane or cyclohexane ring, and the salts of these compounds.
A further embodiment (embodiment 4) of the invention are compounds of formula I in which
R1 and R2 are both hydrogen or together form an additional bond, A represents S (sulfur), Ar represents a benzene derivative of formula (b)
wherein
R5 is halogen, 1-4C-alkoxy or 1-4C-alkoxy which is completely or predominantly substituted by fluorine, R6 is 1-4C-alkyl and R7 is hydrogen or 1-4C-alkyl,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane, cyclohexane, tetrahydrofuran or tetrahydropyran ring, and the salts of these compounds.
Compounds of formula I of embodiment 4 which are to be emphasized are those in which
R1 and R2 together form an additional bond, A represents S (sulfur), Ar represents a benzene derivative of formula (b)
wherein
R5 is 1-2C-alkoxy or 1-2C-alkoxy which is completely or predominantly substituted by fluorine, R6 is methyl R7 is hydrogen,
or wherein
R6 and R7 together and with inclusion of the two carbon atoms, to which they are bonded, form a spiro-linked cyclopentane or cyclohexane ring,
and the salts of these compounds.
Compounds of formula I of embodiment 4 which are particularly to be emphasized are those in which
R1 and R2 together form an additional bond, A represents S (sulfur), Ar represents a benzene derivative of formula (b)
wherein
R5 is methoxy, R6 is methyl and R7 is hydrogen, and the salts of these compounds.
The compounds of formula I are chiral compounds. Chiral centers exist in the compounds of formula I in the positions 4a and 8a. In case Ar represents a benzene derivative of formula (b) there is one further chiral center in the dihydrofuran-ring, if the substituents —R6 and —CH 2 R7 are not identical. However, preferred are in this connection those compounds, in which the substituents —R6 and —CH 2 R7 are identical or together and with inclusion of the two carbon atoms to which they are bonded form a spiro-connected 5-, 6- or 7-membered hydrocarbon ring.
Numbering:
Therefore the invention includes all conceivable pure diastereomers and pure enantiomers, as well as all mixtures thereof independent from the ratio, including the racemates. Preferred are those compounds, in which the hydrogen atoms in the positions 4a and 8a are cis-configurated. Especially preferred in this connection are those compounds, in which the absolute configuration (according to the rules of Cahn, Ingold and Prelog) is S in the position 4a and R in the position 8a. Racemates can be split up into the corresponding enantiomers by methods known by a person skilled in the art. Preferably the racemic mixtures are separated into two diastereomers during the preparation with the help of an optical active separation agent on the stage of the cyclohexanecarboxylic acids or the 1,2,3,6-tetrahydrobenzoic acids (for example, starting compound A1 and A3). As separation agents may be mentioned, for example, optical active amines such as the (+)- and (−)-forms of 1-phenylethylamine [(R)-(+)-1-phenylethylamine=(R)-(+)-α-methylbenzylamine or (S)-(−)-1-phenylethylamine=(S)-(−)-α-methylbenzylamine) and ephedrine, the optical active alkaloids quinine, cinchonine, cinchonidine and brucine.
The compounds according to the invention can be prepared, for example, as described in Reaction Scheme 1:
The reaction of the cyclohexanecarboxylic acids or 1,2,3,6-tetrahydrobenzoic acids with 4-hydrazinotetrahydrothiopyran results in the formation of compounds of formula I. The tetrahydrothiopyran compounds can be converted into sulfones and sulfoxides of formula I through an oxidation reaction.
Suitably, the conversions are carried out analogous to methods which are familiar per se to the person skilled in the art, for example, in the manner which is described in the following examples.
The preparation of the cyclohexanecarboxylic acids and 1,3,5,6-tetrahydrobenzoic acids is described, for example, in WO98/31674, WO99/31090 and WO99/47505.
The substances according to the invention are isolated and purified in a manner known per se, e.g. by distilling off the solvent in vacuo and recrystallising the residue obtained from a suitable solvent or subjecting it to one of the customary purification methods, such as column chromatography on a suitable support material.
Salts are obtained by dissolving the free compound in a suitable solvent (for example a ketone like acetone, methylethylketone, or methylisobutylketone, an ether, like diethyl ether, tetrahydrofuran or dioxane, a chlorinated hydrocarbon, such as methylene chloride or chloroform, or a low molecular weight aliphatic alcohol, such as ethanol, isopropanol) which contains the desired acid, or to which the desired acid is then added. The salts are obtained by filtering, reprecipitating, precipitating with a non-solvent for the addition salt or by evaporating the solvent. Salts obtained can be converted by basification into the free compounds which, in turn, can be converted into salts. In this manner, pharmacologically non-tolerable salts can be converted into pharmacologically tolerable salts.
The following examples illustrate the invention in greater detail, without restricting it. As well, further compounds of formula I, of which the preparation is explicitly not described, can be prepared in an analogous way or in a way which is known by a person skilled in the art using customary preparation methods.
The compounds, which are mentioned in the examples as well as their salts are preferred compounds of the invention.
EXAMPLES
Final Products
1. (cis)-4-(2,3-Dihydro-2,2-dimethyl-7-methoxybenzofuran-4-yl)-2-(tetrahydrothiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
A solution of 2.0 g of starting compound A1 and 2.0 g of 4-hydrazinotetrahydrothiopyran hydrochloride in 20 ml of pyridine is refluxed for 40 h. After evaporating the reaction mixture, the residue is dissolved in diethyl ether. This solution is washed successively with 1N hydrochloric acid and aqueous sodium carbonate. The ether solution is dried over magnesium sulfate and evaporated. Crystallised from methanol. Yield: 0.8 g. M. p. 163-164° C.
2. (cis)-4-(3,4-Dimethoxyphenyl)-2-(1,1-dioxohexahydro-1l 6 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
A solution of 0.65 g of 3-chloroperbenzoic acid in 5 ml of dichloromethane is added slowly to a solution of 0.5 g of starting compound A2 in 5 ml of dichloromethane at 0° C. The resulting mixture is stirred for 1 h at 0° C. and then 1 h at room temperature. Subsequently the mixture is diluted with 100 ml of dichloromethane. This solution is washed successively with a 1 molar solution of sodium thiosulfate and aqueous sodium carbonate, dried over magnesium sulfate and evaporated. The compound is purified by chromatography and crystallised from diethyl ether. Yield: 0.4 g. M. p. 196-198° C.
3. (cis)-4-(3,4-Dimethoxyphenyl)-2-(1-oxo-hexahydro-1l 4 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared from 0.43 g of starting compound A2 and 0.27 g of 3-chloroperbenzoic acid as described for compound 2. Isolated as a mixture of the α and β sulfoxide Yield: 0.2 g. M. p. 158-159° C.
4. (cis)-4-(3-Chloro-4-methoxyphenyl)-2-(tetrahydrothiopyran-4-yl)-4a,5,8,8a -tetrahydro-2H-phthalazin-1-one
A solution of 10 mmol of (cis)-4-(3-Chloro-4-methoxybenzoyl)-1,2,3,6-tetrahydrobenzoic acid (prepared as described in WO99/47505) and 15 mmol of 4-hydrazinotetrahydrothiopyran hydrochloride in 20 ml of pyridine are refluxed for 40 h. After evaporating the reaction mixture, the residue is dissolved in diethyl ether. This solution is washed successively with 1N hydrochloric acid and aqueous sodium carbonate. The ether solution is dried over magnesium sulfate and evaporated. Crystallised from methanol. M. p. 170-171° C.
5. (cis)-4-(3-Chloro4-methoxyphenyl)-2-(1-oxo-hexahydro-1l 4 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared from 5 mmol of compound 4 and 5 mmol of 3-chloroperbenzoic acid as described for compound 2. Isolated as a mixture of the α and β sulfoxide. M. p. 197-199° C.
6. (cis)-4-(3,4-Diethoxyphenyl)-2-(1,1-dioxohexahydro-1l 6 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared from starting compound A4 as described for compound 2. M. p. 195-197° C.
7. (cis)-4-(2,3-Dihydro-2,2-dimethyl-7-methoxybenzofuran-4-yl)-2-(1,1-dioxohexahydro-1l 6 -thiopyran4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared from compound 1 as described for compound 2. M. p. 261-263° C.
8. (4aR,8aS)-(cis)-4-(3,4-Dimethoxyphenyl)-2-(1,1-dioxohexahydro-1lI 6 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
A solution of 5 mmol of the salt of (R)-(+)-α-methylbenzylamine, (cis)-2-(3,4-dimethoxybenzoyl)-1,2,3,6-tetrahydrobenzoic acid (prepared as described in WO98/31674) and 7 mmol of 4-hydrazinotetrahydrothiopyrane hydrochloride in 20 ml of pyridine is refluxed for 18 h after which the solvent is evaporated. The residue is dissolved in ethyl acetate and this solution is washed successively with diluted hydrochloric acid and aqueous sodium carbonate. After drying over magnesium sulfate the solvent is evaporated. The residue is treated with 5 mmol of 3-chloroperbenzoic acid as described for compound 2. Crystallised from methanol. M. p. 200-202° C.
9. (4aS,8aR)-(cis)-4-(3,4-Dimethoxyphenyl)-2-(1,1-dioxohexahydro-1l 6 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared as described for compound 8 using (S)-(−)-α-methylbenzylamine instead of (R)-(+)-α-methylbenzylamine. M. p. 203-204° C.
10. (cis)-4-(3-Cyclopentyloxy-4-methoxyphenyl)-2-(1,1,-dioxohexahydro-1l 6 -thiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared from starting compound A5 and 3-chloroperbenzoic acid as described for compound 2. M. p. 214-215° C.
Starting Compounds
A1. (cis)-2-(2,3-Dihydro-2,2-dimethyl-7-methoxybenzofuran-4-carbonyl)-1,2,3,6-tetrahydro-benzoic Acid
Prepared as described in WO99/31090.
A2. (cis)-4-(3,4-Dimethoxyphenyl)-2-(tetrahydrothiopyran-4-yl)-4a,5,8,8a-tetrahydro-2H-phthalazin-1-one
Prepared as described in WO98/31674.
A3. (cis)-2-(3,4-Diethoxybenzoyl)-1,2,3,6-tetrahydrobenzoic Acid
Prepared as described in WO99/47505.
A4. (cis)4-(3,4-Diethoxyphenyl)-2-(tetrahydropyran-4-yl)-4a,5,8,8a-tetrahydro-2H -phthalazin-1-one
Prepared from 10 mmol of starting compound A3 and 15 mmol of 4-hydrazinotetrahydrothiopyrane hydrochloride as described for compound 1. M. p. 127-129° C.
A5. (cis)-4-(3-Cyclopentyloxy-4-methoxyphenyl)-2-(tetrahydropyran-4-yl)-4a,5,8,8a -tetrahydro-2H-phthalazin-1-one
A solution of 10 mmol of (cis)-4-(3-Cyclopentyloxy-4-methoxybenzoyl)-1,2,3,6-tetrahydrobenzoic acid and 15 mmol of 4-hydrazinotetrahydrothiopyran hydrochloride in 20 ml of pyridine are refluxed for 40 h. After evaporating the reaction mixture, the residue is dissolved in diethyl ether. This solution is washed successively with 1N hydrochloric acid and aqueous sodium carbonate. The ether solution is dried over magnesium sulfate and evaporated. Crystallised from methanol. M. p. 116-117° C.
Commercial Utility
The compounds according to the invention have useful pharmacological properties which make them industrially utilizable. As selective cyclic nucleotide phosphodiesterase (PDE) inhibitors (specifically of type 4), they are suitable on the one hand as bronchial therapeutics (for the treatment of airway obstructions on account of their dilating action but also on account of their respiratory rate- or respiratory drive-increasing action) and for the removal of erectile dysfunction on account of their vascular dilating action, but on the other hand especially for the treatment of disorders, in particular of an inflammatory nature, e.g. of the airways (asthma prophylaxis), of the skin, of the intestine, of the eyes, of the CNS and of the joints, which are mediated by mediators such as histamine, PAF (platelet-activating factor), arachidonic acid derivatives such as leukotrienes and prostaglandins, cytokines, interleukins, chemokines, alpha-, beta- and gamma-interferon, tumor necrosis factor (TNF) or oxygen free radicals and pro-teases. In this context, the compounds according to the invention are distinguished by a low toxicity, a good enteral absorption (high bioavailability), a large therapeutic breadth and the absence of significant side effects.
On account of their PDE-inhibiting properties, the compounds according to the invention can be employed in human and veterinary medicine as therapeutics, where they can be used, for example, for the treatment and prophylaxis of the following illnesses: acute and chronic (in particular inflammatory and allergen-induced) airway disorders of varying origin (bronchitis allergic bronchitis, bronchial asthma, emphysema, COPD); dermatoses (especially of proliferative, inflammatory and allergic type) such as psoriasis (vulgaris), toxic and allergic contact eczema, atopic eczema, seborrhoeic eczema, Lichen simplex, sunburn, pruritus in the anogenital area, alopecia areata, hypertrophic scars, discoid lupus erythematosus, follicular and widespread pyodermias, endogenous and exogenous acne, acne rosacea and other proliferative, inflammatory and allergic skin disorders; disorders which are based on an excessive release of TNF and leukotrienes, for example disorders of the arthritis type (rheumatoid arthritis, rheumatoid spondylitis, osteoarthritis and other arthritic conditions), disorders of the immune system (AIDS, multiple sclerosis), graft versus host reaction, allograft rejections, types of shock (septic shock, endotoxin shock, gram-negative sepsis, toxic shock syndrome and ARDS (adult respiratory distress syndrome)) and also generalized inflammations in the gastrointestinal region (Crohn's disease and ulcerative colitis); disorders which are based on allergic and/or chronic, immunological false reactions in the region of the upper airways (pharynx, nose) and the adjacent regions (paranasal sinuses, eyes), such as allergic rhinitis/sinusitis, chronic rhinitis/sinusitis, allergic conjunctivitis and also nasal polyps; but also disorders of the heart which can be treated by PDE inhibitors, such as cardiac insufficiency, or disorders which can be treated on account of the tissue-relaxant action of the PDE inhibitors, such as, for example, erectile dysfunction or colics of the kidneys and of the ureters in connection with kidney stones. In addition, the compounds of the invention are useful in the treatment of diabetes insipidus and conditions associated with cerebral metabolic inhibition, such as cerebral senility, senile dementia (Alzheimer's disease), memory impairment associated with Parkinson's disease or multiinfarct dementia; and also illnesses of the central nervous system, such as depressions or arteriosclerotic dementia.
The invention further relates to a method for the treatment of mammals, including humans, which are suffering from one of the abovementioned illnesses. The method is characterized in that a therapeutically active and pharmacologically effective and tolerable amount of one or more of the compounds according to the invention is administered to the ill mammal.
The invention further relates to the compounds according to the invention for use in the treatment and/or prophylaxis of illnesses, especially the illnesses mentioned.
The invention also relates to the use of the compounds according to the invention for the production of medicaments which are employed for the treatment and/or prophylaxis of the illnesses mentioned.
The invention furthermore relates to medicaments for the treatment and/or prophylaxis of the illnesses mentioned, which contain one or more of the compounds according to the invention.
Additionally, the invention relates to an article of manufacture, which comprises packaging material and a pharmaceutical agent contained within said packaging material, wherein the pharmaceutical agent is therapeutically effective for antagonizing the effects of the cyclic nucleotide phosphodiesterase of type 4 (PDE4), ameliorating the symptoms of an PDE4-mediated disorder, and wherein the packaging material comprises a label or package insert which indicates that the pharmaceutical agent is useful for preventing or treating PDE4-mediated disorders, and wherein said pharmaceutical agent comprises one or more compounds of formula I according to the invention. The packaging material, label and package insert otherwise parallel or resemble what is generally regarded as standard packaging material, labels and package inserts for pharmaceuticals having related utilities.
The medicaments are prepared by processes which are known per se and familiar to the person skilled in the art. As medicaments, the compounds according to the invention (=active compounds) are either employed as such, or preferably in combination with suitable pharmaceutical auxiliaries, e.g. in the form of tablets, coated tablets, capsules, suppositories, patches, emulsions, suspensions, gels or solutions, the active compound content advantageously being between 0.1 and 95%.
The person skilled in the art is familiar with auxiliaries which are suitable for the desired pharmaceutical formulations on account of his expert knowledge. In addition to solvents, gel formers, ointment bases and other active compound excipients, for example antioxidants, dispersants, emulsifiers, preservatives, solubilizers or permeation promoters, can be used.
For the treatment of disorders of the respiratory tract, the compounds according to the invention are preferably also administered by inhalation. To do this, these are either administered directly as a powder (preferably in micronized form) or by atomizing solutions or suspensions which contain them. With respect to the preparations and administration forms, reference is made, for example, to the details in European Patent 163 965.
For the treatment of dermatoses, the compounds according to the invention are in particular administered in the form of those medicaments which are suitable for topical application. For the production of the medicaments, the compounds according to the invention (=active compounds) are preferably mixed with suitable pharmaceutical auxiliaries and further processed to give suitable pharmaceutical formulations. Suitable pharmaceutical formulations are, for example, powders, emulsions, suspensions, sprays, oils, ointments, fatty ointments, creams, pastes, gels or solutions.
The medicaments according to the invention are prepared by processes known per se. The dosage of the active compounds is carried out in the order of magnitude customary for PDE inhibitors. Topical application forms (such as ointments) for the treatment of dermatoses thus contain the active compounds in a concentration of, for example, 0.1-99%. The dose for administration by inhalation is customarly between 0.1 and 3 mg per day. The customary dose in the case of systemic therapy (p.o. or i.v.) is between 0.03 and 3 mg/kg per day.
Biological Investigations
In the investigation of PDE 4 inhibition on the cellular plane, the activation of inflammatory cells is ascribed particular importance. An example is FMLP (N-formyl-methionyl-leucyl-phenylalanine)-induced superoxide production of neutrophilic granulocytes, which can be measured as luminol-amplified chemiluminescence. (Mc Phail L C, Strum S L, Leone P A and Sozzani S, The neutrophil respiratory burst mechanism. In “Immunology Series” 57: 47-76, 1992; ed. Coffey R G (Marcel Decker, Inc., New York-Basel-Hong Kong)).
Substances which inhibit chemiluminescence and cytokine secretion and the secretion of proinflammatory mediators on inflammatory cells, in particular neutrophilic and eosinophilic granulocytes, T-lymphocytes, monocytes and macrophages are those which inhibit PDE 4. This isoenzyme of the phosphodiesterase families is particularly represented in granulocytes. Its inhibition leads to an increase in the intracellular cyclic AMP concentration and thus to the inhibition of cellular activation. PDE 4 inhibition by the substances according to the invention is thus a central indicator for the suppression of inflammatory processes. (Giembycz M A, Could isoenzyme-selective phosphodiesterase inhibitors render bronchodilatory therapy redundant in the treatment of bronchial asthma?. Biochem Pharmacol 43: 2041-2051, 1992; Torphy T J et al., Phosphodiesterase inhibitors: new opportunities for treatment of asthma. Thorax 46: 512-523, 1991; Schudt C et al., Zardaverine: a cyclic AMP PDE ¾ inhibitor. In “New Drugs for Asthma Therapy”, 379-402, Birkhäuser Verlag Basel 1991; Schudt C et al., Influence of selective phosphodiestera inhibitors on human neutrophil functions and levels of cAMP and Ca; Naunyn-Schmiedebergs Arch Pharmacol 344; 682-690, 1991; Tenor H and Schudt C. Analysis of PDE isoen-zyme profiles in cells and tissues by pharmacological methods. In “Phosphodiesterase Inhibitors”, 21-40. “The Handbook of Immunopharmacology”, Academic Press, 1996; Hatzelmann A et al., Enzymatic and functional aspects of dual-selective PDE¾-Inhibitors. In “Phosphodiesterase Inhibitors”, 147-160, “The Handbook of Immunopharmacology”, Academic Press, 1996.
Inhibition of PDE 4 Activity
Methodology
The activity test was carried out according to the method of Bauer and Schwabe, which was adapted to microtitre plates (Naunyn-Schmiederberg's Arch. Pharmacol. 311, 193-198, 1980). In this test, the PDE reaction is carried out in the first step. In a second step, the resultant 5′-nucleotide is cleaved to the uncharged nucleoside by a snake venom 5′-nucleotidase from Crotalus Atrox. In the third step, the necleoside is separated from the remaining charged substrate on ion exchange columns. The columns are eluted directly into minivials using 2 ml of 30 mM ammonium formate (pH 6.0), to which a further 2 ml of scintillation fluid is added for counting.
The inhibitory values determined for the compounds according to the invention follow from the following table A which the numbers of the compounds correspond to the numbers of the examples.
TABLE A
Inhibition of PDE4 acitivity
[measured as −logIC 50 (mol/l)]
compound
−logIC 50
1
9.34
2
8.45
3
8.51
5
8.20
6
8.02
7
9.00
9
9.20
10
9.43
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The compounds of formula (I) in which R1, R2, A and Ar have the meanings as given in the description are novel effective PDE4 inhibitors.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a printing plate mounting system and method therefor. More particularly, the invention relates to a flexographic printing plate mounting system, physical register record plate (PRRP) and method employing the mounting system and PRRP.
2. Related Art
Presently, there exists a number of flexographic printing plate mounting systems. Today, such systems typically employ some method of registering the flexographic printing plate onto a plate cylinder by aligning a pair of microdots formed in the printing plate with respect to a central axis of the plate cylinder. The mounting systems which employ the use of microdots operate on the principal of positioning two microdots which are perpendicular to the making direction of the web.
A trend in the industry has been to use a pair of cameras which are ideally in parallel with a shaft of the mounting plate cylinder. Each camera is operatively connected to a split screen monitor to display the position of the microdots. The microdots, and in turn the printing plate, are manually manipulated to bring the microdots into a center screen, thus registering the plate.
A problem which exists with the use of the microdots is that those alignment techniques currently employed today require a relatively high degree of human intervention to make judgments on alignment and positioning. Frequently, this intervention results in error of the registering of plates. Specifically, each plate may vary slightly in registration from another by virtue of the mounter displacing the microdots slight amounts each time a centering of the microdots is accomplished.
One requirement for high multicolor quality printing to be accomplished is that all of the printing surfaces on the respective color printing plates are properly positioned on their respective plate rollers so that when the web being printed upon is fed into contact with printing plates mounted on the successive plate rollers in the press, the several colors will be applied properly to the web in the desired exact position to form the composite images which together reproduce the original photograph being duplicated. This process is also important in some black and white in some applications.
There remains a need in the art to have a mounting device and method employing the same which is less cumbersome, less expensive and reduces the amount of error which is introduced in registering various plates. In essence, there is a need for a simpler system for mounting flexographic printing plates.
SUMMARY OF THE INVENTION
An object of the present invention is to improve printing plate mounting systems.
Another object is to improve the system and method for mounting flexographic printing plates.
Accordingly, the present invention is directed to a system for mounting flexible printing plates, including a sticky back covered plate cylinder, a plate support surface, means operably connected to the cylinder for drawing the cylinder toward the support surface in a manner to establish a uniform contact line, a physical register record plate (PRRP) having a microring formed on a surface thereof, the PRRP being arranged in a fixed position on the support surface such that the microring is in a predetermined position in relation to the contact line, a printing plate having a microdot formed on a surface thereof, wherein the microdot is of a size and configuration to be generally complimentarily received within the microring when positioned thereagainst to place the printing plate in condition for mounting by the plate cylinder. In other words, in a mounting system which utilizes a sticky back plate cylinder, a plate support surface and a flexographic printing plate having a microdot formed on a surface thereof, there is provided a PRRP, which includes a moldable substrate having a microring formed a surface thereof and wherein the microring has a receiving and holding surface generally complimentary to an outer surface of the microdot, and wherein the PRRP is fixably positionable onto the plate support surface such that when the microdot is inserted within the microring, the printing plate is positioned for registration onto the plate cylinder. Additionally, the printing plate may be formed with a pair of microdots and the PRRP may be formed with a complimentary pair of microrings.
In another embodiment, the invention includes a method for preparing flexible printing plates for mounting, comprising the steps of forming a flexible printing plate having a microdot thereon, forming a PRRP having a microring formed thereon, wherein the microring is configured to have a receiving surface generally complimentary to an outer surface of the microdot; orienting the PRRP onto a surface; and interfacing the printing plate with the PRRP such that the microdot is positioned within the microring to ready the printing plate for mounting.
Other objects and advantages will be more apparent from reading the following drawings and description hereto.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a printing plate made in accordance with the present invention having a pair of microdots formed thereon.
FIG. 2 is an end cross sectional view the printing plate shown in FIG. 1.
FIG. 3 is a plan view of a physical register record plate (PRRP) made in accordance with the invention having a pair of microrings formed thereon.
FIG. 4 is an end cross sectional view of the PRRP shown in FIG. 3.
FIG. 5 is an end cross sectional view of the printing plate face to face with the PRRP with the microdots partially disposed into the microrings.
FIG. 6 is a perspective view of a device for completing the mounting of a flexographic printing plate in accordance with the present invention having the PRRP of FIG. 3 disposed thereon.
FIG. 7 is a side view of the device and PRRP shown in FIG. 6 having the printing plate of FIG. 1 disposed thereon in a manner depicted in FIG. 5.
FIG. 8 is another side view of the device and plates shown in FIG. 7.
FIG. 9 is another side view of the device and PRRP as shown in FIG. 6 having the printing plate attached to a plate cylinder of the device.
FIG. 10 is perspective view of the device and PRRP as shown in FIG. 6 having the printing plate attached to a plate cylinder of the device.
FIG. 11 is another embodiment of the present invention with the PRRP and printing plate disposed in a manner depicted in FIG. 5 and having a plate boring apparatus in connection therewith.
FIG. 12 is a plan view of a PRRP having pairs of microrings formed thereon in relation to a pair of printing plates each having a pair of microdots which correspond to one of the pair of microrings.
FIG. 13 is a perspective view of the device with the printing plates of FIG. 12 face to face with the PRRP of FIG. 12 with the microdots partially disposed into the microrings.
FIG. 14 is an end view of another embodiment of a mounting device for use in the present invention.
FIG. 15 is an end view of the device in FIG. 14.
FIG. 16 is another end view of the device in FIG. 14 in another operational position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, a flexographic printing plate is generally referred to by the numeral 10. The plate 10 may be formed from, for example, a photopolymer of the type from: Dupont Cyrel, B.A.S.F./NAPP Nylo-flex, Hercules pourable polymers, W.R. Grace Flexlite or Supratech Flexceed; or a rubber of the type from: Uniroyal, Good-Year, B.F. Goodrich, Mosstype or Graphic-Arts Rubber. Such materials can typically be obtained in sizes up to 60"×120".
The printing plate 10 is produced in a conventional manner known to the art and as described in Flexography--Principles and Practices--Published by Flexographic Technical Association--Library of Congress Catalog Card No. 80-69506, Chapter VI, Engraving and Printing Pates, pages 149-183, incorporated herein by reference. For the materials listed above, the photopolymer is exposed to an ultraviolet light on one side for a predetermined period to harden and cure the photopolymer to a predetermined depth of a relief to be formed on the other side for the etching process. The other side of the plate is then covered with a photographic negative and exposed to the ultraviolet light to harden the printing surface through to the pre-hardened depth. The photographic negative is removed from the printing plate and the printing plate is washed with a polymer solvent to remove the unhardened material thus providing a printing surface 12. The plate 10 may be more fully hardened if desired.
In recent years, the photographic negative has been generated using the aid of a computer. This has enabled the formation highly accurate graphic artwork. Particularly, the artwork can be easily positioned at any desired x and y coordinates. This positioning ability precipitated the invention of the microdots as shown in 14 in FIGS. 1 and 2, a pair of small dots formed in the plate 10, which have been widely used in the industry as a registering aid. The microdots are uniformly formed along an x/y coordinate (via creating a small transparent circle in the photographic negative adjacent the art design) in the plate 10 and have been used principally in the registering process by attempting to align these microdots with a common x/y coordinate of another surface to permit the plate 10 to be mounted in register to a plate cylinder.
In the present invention, a departure from the related art has been made by recognizing that complimentary computer graphic artwork can be created with respect to the microdots. In other words, a photographic negative is formed having a pair of transparent microrings having the same center x, y coordinates as the microdots. The inner diameter of the microring is slightly greater than the diameter defining the transparent circle to account for shouldering effect of the polymer upon hardening.
A physical register record plate (PRRP) 16 is formed in the following manner. The PRRP 16 may be of the type: having a metal backing and a photopolymer of the type described above or B.A.S.F./NAPP Nylo-Print, Toray, Innovative Equip., Innoplate, JET U.S.A., Jet-Plate or Print-Tight; rubber of the type described above; or photo-etched metals such as magnesium, copper or steel. For a purpose of the present invention, a photopolymer type is employed. Similarly, after being prepped, a photographic negative having a pair of transparent rings (centered at positions located identically to the center positions of the transparent circles of the photographic negative for forming the microdots) is placed over the photopolymer and exposed to UV light and subsequently washed for forming the PRRP 16 having the hardened microrings 18 thereon.
Ideally, the bottom surface 20 formed within the microrings 18 will be slightly less than the size of the microdots 14 such that the terminal end 22 of the microdots 20 do not touch the bottom surface 20 of the microrings 18. As seen in FIG. 5, the microdots 14 partially seat within the microrings 18, which permits easier separation of the plate 10 from the PRRP 16.
The mounting device 24 depicted in FIGS. 6-10 and 13, includes a support base 26, a pair of arms 28 removably hingedly connected at one end 30 to the support base 26. Rotatably removably connected at the other end 32 of the arms 28 is a plate cylinder 36 onto which the printing plate 10 is to be mounted. Commonly, the plate cylinder 36 will include a sticky back 38 for affixing the printing plate 10.
In operation, the PRRP 16 is fixedly disposed onto a surface 40 of the base 26 in a manner to place the microrings 18 in register or alignment with the plate cylinder 36, typically a central axis of the plate cylinder 36. This can be done by providing markings 42 on the surface 40 and aligning the microrings 18 with the markings and then fixing the PRRP 16 to the surface 40. While the PRRP 18 may be skewed, but this will not matter as all of the printing plates 10 will be mounted off the same PRRP 16 for any one particular printed design and, thus, while slightly skewed with the plate cylinder 36, all plates 10 are in register with one another and a multicolor print, for example, are produced in substantially perfect register.
Each time a plate 10 is to be placed down on the surface 40 for mounting, the microdots 14 are first positioned within the microrings 18. Then, the arms 28 are actuated to a point wherein the sticky back 38 of the plate cylinder 36 is brought into contact with the back surface 44 of the plate 10. The arms 28 are then actuated in opposite direction such that the plate cylinder 36 is disposed away from the surface 40 having the printing plate 10 adhered thereto and to permit the plate 10 to be rolled into position on the plate cylinder 36. The plate cylinder 36 can then be removed from the arms 28 for use in a desired application.
Alternatively, as seen in FIGS. 14-16, the mounting device 50 is employable for use in mounting varying size plate cylinders. The mounting device 50 includes a support base 52, support members 54 fixedly connected to the base 52 in a predetermined alignment relationship to the base 52, bored surfaces 55, threaded shafts 56 and means 58 for reciprocating the threaded shafts 56. One of the shafts 56 extends through one of the bore surfaces 55 and has fixed to one end a bearing member 60 connected thereto which slidably fits between the support members 54. A plate cylinder 62 having a shaft 64 is disposed between the support members 54a and 54b such that the shaft 64 bears upon the bearing member 60. The shaft 64 is preferably of a diameter slightly less than the distance between support members 54b (wherein the distance between support members 54a and support member 54b are the same) to keep the plate cylinder 62 in a predetermined alignment with respect to the PRRP 16.
The reciprocating means 58 includes a crank 66 and operably connected arms 68 and threaded wheels 70. The wheels 70 are operably connected to the threaded shafts 56 such that when the crank 66 is turned, the wheels 70 rotate to cause the shafts 60 to uniformly move between the support members 54b (likewise between 54a) thus moving the plate cylinder 62 toward or away from the support base 52 depending upon the direction the crank 66 is turned. It is recognized that other mechanisms may be employed to accomplish this result, such as a hydraulic mechanism.
The mounting process of the plate 10 is essentially the same for the device 50 as that described for the device 24, wherein a difference exists in how the plate cylinders 38 and 62 are brought into contact with the plate 10. It is believed that the device 50 provides an additional feature of being able to easily mount in register plates of varying sizes onto complimentary sized plate cylinders by virtue the shaft 62 remaining uniformly positioned and centered over the microrings 18 regardless of the plate cylinder size.
While the present invention has discussed the use of microdots and microrings in conjunction with the mounting system, there is a myriad of other male female configurations which may be employed to accomplish the same result and accordingly are equivalents in function to the present invention. For example, a register mark is typically formed on every color plate. A complimentary female register mark may be formed on the PRRP for use in mounting. Also, it may be that the print surface design is symmetrical about a center point and a single microdot or a central feature of the print surface may be used in conjunction with a single microring or complimentary feature in which to register the printing plate.
As shown in FIG. 11, there is provided an additional embodiment. Here a support base 72 includes a bored surface 74 and an operably associated plate boring apparatus 76 is used to bore a hole in the plate 10 once positioned onto the PRRP 16. In this regard, the surface 78 defining the hole can be used in conjunction with certain mounting devices which mount plates by registering about a bored surface.
As previously discussed, some of the plate materials described above are limited in their size in which they can be formed. In other cases, it is desirous to prepare different strips of printed art work which can be ganged together for a run. FIG. 12 shows a PRRP 80 having microrings 82 and 84 and printing plates 86 with microdots 88 and printing plate 90 with microdots 92. Here, the microdots 88 and 92 are seated into microrings 82 and 84, respectively. Thus, the plates 86 and 90 can be ganged together for mounting as shown in FIG. 13. The PRRP 80 notably is also capable of registering and mounting each plate individually.
By so providing the present invention, there has been created a novel and improved printing plate mounting system which substantially eliminates human error in aligning and registering the flexographic printing plates onto a plate cylinder. The preset invention has also substantially reduced the cost and ease in which the flexographic printing plate mounting process is accomplished.
There will be many modifications and variations to the present invention which will be readily apparent to those skilled in the art and the embodiment set forth above is put forth by way of example for flexible printing plate mounting system but will have application to other techniques such as letter press, for example. Additionally, it is contemplated that the PRRP may be placed on any fixed plate support or slidably movable fixable plate support which is movable along the contact line described above. Accordingly, such modifications and variations should be within the scope of the claims appended hereto.
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A flexible printing plate mounting system, physical register record plate (PRRP) and method employing the same, wherein the system includes a sticky back covered plate cylinder, a plate support surface, arms operably connected to the cylinder for drawing the cylinder toward the support surface in a manner to establish a uniform contact line, the PRRP having a microring formed on a surface thereof and arranged in a fixed position on the support surface such that the microring is in a predetermined position in relation to the contact line, a printing plate having a microdot formed on a surface thereof, wherein the microdot is of a size and configuration to be generally complimentarily received within the microring when positioned thereagainst to place the printing plate in condition for mounting by the plate cylinder.
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PRIORITY
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 61/802,609, filed Mar. 16, 2013, which is herein incorporated by reference in its entirety, claims the benefit of U.S. Provisional Application Ser. No. 61/837,924, filed Jun. 21, 2013, which is herein incorporated by reference in its entirety, and also claims the benefit of U.S. Provisional Application Ser. No. 61/891,844, filed Oct. 16, 2013, which is herein incorporated by reference in its entirety.
THE FIELD OF THE INVENTION
[0002] The present invention relates to furniture. In particular, examples of the present invention relates to a modular furniture system which provides improved joints allowing tool-less assembly and increased stability.
BACKGROUND
[0003] Many persons desire modular furniture. Modular furniture is often assembled by the end user from flat pieces and is thus easy to store and transport in the un-assembled form. Modular furniture often suffers from instability, and in some instances modular furniture is made overly complex or uses more permanent fastening or construction methods to stabilize the furniture. This, however, makes the furniture more cumbersome for the end user and reduces some of the portability and ease of use associated with this type of furniture. Additionally, the use of fasteners such as screws or nails to stabilize the furniture is often problematic in the long term as these fasteners become loose with use and movement of the furniture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Non-limiting and non-exhaustive examples of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
[0005] FIGS. 1 through 8 show a shelving grid and parts thereof.
[0006] FIGS. 9 through 16 show furniture joints and furniture with a shelving grid.
[0007] FIGS. 17 through 23 show joints used in furniture shelves, dividers, and back panels.
[0008] FIGS. 24 through 26 show a furniture tension joint.
[0009] FIGS. 27 through 29 show a furniture door.
[0010] FIGS. 30 through 45 show shelving/furniture grids and parts which may be assembled together to form larger units.
[0011] FIGS. 46 through 48 show the application of a wave shape to the front of a furniture grid.
[0012] FIGS. 49 through 53 show braces for modular furniture.
[0013] FIGS. 54 through 57 show connectors for attaching panels of modular furniture together.
[0014] FIGS. 58 through 71 shows printed boxes/bins which may be used with a shelving grid.
[0015] Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various examples of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.
[0016] It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The examples shown each accomplish various different advantages. It is appreciated that it is not possible to clearly show each element or advantage in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the examples in greater clarity. Similarly, not every example need accomplish all advantages of the present disclosure.
DETAILED DESCRIPTION
[0017] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention.
[0018] Reference throughout this specification to “one embodiment”, “an embodiment”, “one example” or “an example” means that a particular feature, structure or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, “one example” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.
[0019] Toolless Grid Storage
[0020] FIGS. 1 and 2 illustrate how a grid shelving unit can be constructed from one set of panels with a notch or slot in the front and another set of panels with a notch or slot in the back. For example, the vertical panels 10 may have slots 18 extending in from the front edge of the panels approximately half of the way through the panel and the horizontal panels 14 may have slots 18 extending into the panel from the back edge of the panel approximately half way through the panel. The notches or slots 18 in the panels 10 , 14 may be shaped in an S-shape or curved or bent shape which causes the panel which is inserted into the slot to bend when inserted into the slot. The slot 18 causes the panel 10 , 14 to remain bent while the furniture is assembled. The slot may have a slot width which is wider than the adjoining panel's thickness while also having a curved or bent shape which presents an unobstructed pathway through the slot which is narrower than the panel thickness. This allows for interference that helps keep the panels together and strengthens the furniture.
[0021] A grid can be made from multiple horizontal and vertical pieces which have slots cut in them approximately half way through them. Typically the most sturdy and aesthetically pleasing shelves are made by forming the horizontal pieces with the slots in the back and the vertical pieces with the slots in the front. This offers greater support to the front horizontal edge of the resulting shelf at the expense of the stability at the back horizontal edge. This is advantageous as the front of the shelf typically receives a higher of use and interaction from a person as objects are placed on the shelf and removed from the shelf. The front vertical edge does not need the same stability as it is not weight bearing. The horizontal and vertical pieces could be swapped, but this configuration may be stronger because the front edge of the horizontal pieces is not broken and should perform better for weight bearing at the front edge.
[0022] FIG. 3 illustrates a single joint of a piece of furniture such as a shelving grid which is made from a horizontal piece 14 and a vertical piece 10 . FIG. 4 illustrates a portion of a planar piece 22 (which could be a portion of a vertical piece 10 or a horizontal piece 14 ) with a slot 18 . The slot 18 is not straight, but may be a uniform width. The uniform slot width 26 is greater than the thickness of the piece it accepts, and the narrowest extended width 30 through the slot is less than the thickness of the piece it accepts. Therefore, as the parts 10 , 14 are slid together, the piece being inserted into a slot 18 has to bend. This creates pressure and friction between the bent piece 10 , 14 and the walls of the slot 18 , holding the pieces securely together without nails or glue while allowing for easy assembly and disassembly. The slot width 26 is relatively close to the thickness of the inserted panel, and may often be between about 10 and 50 percent greater than the panel thickness. The open extended width 30 through the slot 18 is often between about 90 and 50 percent of the thickness of the inserted panel. The slot 18 is typically relatively straight overall so that the inserted panel, although bent to create a stressed joint, remains relatively flat. The overall outside width of the slot between the extremes of the slot may be between about 10 and 50 percent greater than the thickness of the inserted panel.
[0023] The slot width 26 could be made less than the thickness of the inserted piece, but this could require that the piece with the slot would have to bend in plane, causing high and unnecessary stress. To achieve a tight fit in straight cut slot without being so tight that assembly is difficult, very tight tolerances in the material thickness and the slot widths have to be held. The curved-slot configuration shown in these figures allows for more easily attainable tolerances in the material thickness and slot dimensions. The panels 10 , 14 are often made of a wood such as plywood or a plastic such as ABS. These materials have a degree of flexibility and will bend elastically when inserted into a slot 18 to provide the discussed rigidity. The material used to form the shelving grid pieces 10 , 14 may often be about one quarter of an inch thick, and may be between one eighth and three eighths of an inch thick in many examples.
[0024] FIG. 5 shows a variation of the slot 18 with more profile variation. As shown, the slot may be a bent shape such as the zig-zag shape shown. The slot 18 may have a single bend or multiple bends and provides a slot 18 with a slot width 26 which is greater than the thickness of the material used to create the piece 10 , 14 and provides an unobstructed channel 30 through the slot which is narrower than the material used to create the piece 10 , 14 so that the piece 10 , 14 inserted into the slot must bend when inserted and remain bent in an assembled configuration.
[0025] FIG. 6 shows a variation where a slot 18 is slightly wider than the material used to make the pieces 10 , 14 for the rearmost majority of the slot and is narrower for a section 34 at the front of the slot 18 . This requires a degree of in-plane bending or stretching of the section 22 of the piece 10 , 14 , but results in a lower stress than an entire slot 18 formed narrower than the material of pieces 10 , 14 as the material has more room to distribute the stress and stress is not concentrated at the root of the slot. A slot 18 as shown in FIG. 6 may be combined with a slot 18 shown in FIG. 4 or 5 in creating a joint as shown in FIG. 3 . A slot 18 as shown in FIG. 6 may be formed at the front of the vertical pieces 10 while a slot 18 as shown in FIG. 4 or 5 may be formed at the back of the horizontal pieces 14 . This results in a shelving grid where the horizontal pieces 14 are held tightly but are not bent by the slots in the vertical pieces 10 to provide a flat shelf area while the vertical pieces 10 are bent by the slots in the horizontal pieces 14 to provide a secure and stable piece of furniture.
[0026] A benefit of a stressed joint (i.e. a joint with panels 10 , 14 which are held in an elastically bent configuration when assembled) is that it will stay together under typical loads and movement, and also eliminates the play or movement in furniture that can make it feel unstable or cheap. Additionally it can make the furniture quieter. No tools are required to assemble the joint and no fasteners are needed to keep the joint together.
[0027] Placement of Interference Joints
[0028] This interference and elastic bending of the panels 10 , 14 can make assembling and disassembling the panels into furniture difficult. This is particularly true when a large piece of furniture is assembled, as the force required to assemble a single joint is multiplied by the number of joints formed by a given panel or piece 10 , 14 . One way to remedy this problem is to only make the slots near the end of each panel 10 , 14 have interference. That is to say that only the slots near the end of each panel 10 , 14 hold the panel which is received into the slot in a bent configuration when assembled. For example, in FIGS. 7 and 8 the slots 18 A or the slots 18 A and 18 B could have interference and cause the inserted panel to bend as discussed, but not the slots 18 B, 18 C, 18 D or 18 C, 18 D. The slots 18 which are not shaped to bend the received panel 10 , 14 may be straight and may be cut with a width which is close to but slightly larger than the thickness of the material used to make the panels 10 , 14 . In the assembled shelving unit, both slots 18 A would have interference at the corners of the shelving unit and all slots 18 would have at least some interference around the perimeter of the shelving unit while no slots 18 would have interference in the center. This may provide a shelving unit which is adequately stable without requiring unnecessarily high forces to assemble the shelves.
[0029] Captive Grid
[0030] The same joints discussed above with panels 10 , 14 and slots 18 can be used within a casework created with another material or another type of joints. Shelves for small objects can be made to be subdivided by an internal grid with intersecting slots which is placed into a case formed by thicker material. The internal grid can be formed in the same way illustrated above.
[0031] FIGS. 9 and 10 show a cubby shelf 38 for small objects like shoes. The shelf may be designed to have equal sized openings. The illustrated shelf has openings that progressively get larger towards the bottom of the shelf. An advantage to this design is that space for storing shoes is maximized as not all shoes are the same size.
[0032] The cubby shelf 38 may be formed from vertical side pieces 42 and horizontal top and bottom pieces 46 . The top and bottom pieces 46 and side pieces 42 may be attached together differently than the divider grid inside of the cubby shelf 38 . The side pieces 42 and top and bottom pieces 46 may be connected with interlocking tabs and slots. The tabs may extend through slots and then be moved in a transverse direction to lock the tabs into the slots. The divider grid may be formed of vertical panels 10 and horizontal panels 14 . The vertical panels 10 and horizontal panels 14 may include slots 18 and may connect together in the manner discussed with respect to FIGS. 1 through 8 above.
[0033] Captive Back Joint
[0034] FIGS. 11 and 12 illustrate how the vertical panels 10 and horizontal panels 14 may be attached to the vertical sides 42 or horizontal top and bottom panels 46 of a piece of furniture. The vertical panels 10 and horizontal panels 14 may be held captive in the panels 42 , 46 . Additionally, the furniture 38 may have one or more back panels 50 . The back panels 50 may be attached to the size panels 42 or top and bottom panels 46 . A joint can be made which is blind to the outside of the panels 42 , 46 and uses tension when assembled to create a joint that provides stability, as well as doesn't make any noise from shifting.
[0035] As shown in FIG. 11 , a joint between a panel such as a back panel 50 may include a blind slot 54 cut into the side panel 42 and a tab 58 which is inserted into the slot 54 . The blind slot 54 may be formed so that it does not extend through the panel 42 and is not seen from the outside of the furniture 38 . The tab 58 may be placed into the slot 54 as the furniture 38 is assembled and held in place by the joints which secure the side panels 42 to the top and bottom panels 46 . Although discussed as jointing the back panel 50 , such a tab 58 and slot 54 may be used to secure the vertical panels 10 and horizontal panels 14 of the shelving grid to the furniture 38 .
[0036] Such a joint ( 54 , 58 ) can be made with thinner materials than are typically used for other portions of the case. Thus, the joint may be used to join a thin back 50 or panels 10 , 14 to thicker panels 42 , 46 of the furniture. FIG. 12 shows a perspective view of the assembled joint of FIG. 11 . FIGS. 13 and 14 show additional views of such a joint. The slot 54 may be cut into the panel 42 at a slight angle relative to the alignment of the panel 50 , requiring the tab 58 to be twisted slightly to fit into the slot 54 . This bends the panel 50 out of plane when assembled and places the joint under tension, stiffening the joint and strengthening the furniture 38 . FIGS. 13 , 14 , and 15 illustrate how the slot 54 and tab 58 may be cut with an extra relieved area adjacent inside corners to allow the tab 58 to seat fully into the slot 54 and to fit against the ends of the slot while allowing both to be cut with a router bit 62 , allowing the pieces to be fully cut on a cnc router table or the like.
[0037] FIG. 16 shows another example of how such a joint may be used. The joint can be used in furniture such as a toy kitchen set to join a thin back panel 50 to a thicker side panel 42 . The tab 58 may be sized within the slot 54 to fit quite closely to prevent the furniture sides 42 from being displaced vertically relative to each other and skewing the furniture 38 . Additional stability can be achieved if the tabs 58 are long enough to extend to the bottom of the slot 54 .
[0038] Captive Back Joint (Z Form)
[0039] FIGS. 17 , 18 and 19 show an additional variation of a joint between adjacent furniture panels. As an example, the joint may be formed between a back panel 50 and adjacent vertical panels 10 , 42 or horizontal panels 14 , 46 of a piece of furniture. The joint may also be used between other furniture panels which are disposed on intersecting planes such as horizontal divider panels 14 and vertical case panels 42 .
[0040] By modifying the shape of the tabs 58 used on the panel 50 , multiple back panels 50 can be used to cover the entire back of a piece of furniture. The tabs 58 are z or s shaped so they nest with a corresponding tab 58 on an adjacent panel. A vertical or horizontal panel 10 , 42 such as from the furniture case or from an internal shelving grid is deeper than other internal grid components and passes between the back panels 50 and has slots 66 that the tabs 70 pass through. As is seen, the tabs 70 are cut so that a first tab and a second tab from adjacent panels 50 nest together and together fill the slot 66 . The tabs 70 may be symmetrical and thus ease design and production constraints and improve the modularity of the pieces used to assemble the furniture. The tabs 70 may have a projection which extends outwardly and a recess cut inwardly into the panel 50 . The recess may be a similar size and shape as the projection and receives the projection from a tab on an adjacent panel. For such a design, a single tab 70 may not completely fill a slot 66 and may leave a gap and allow some movement, but two adjoining tabs 70 may fill the slot 66 and prevent movement of the tabs within the slot. The tabs 70 may include a projecting portion which extends through the slot and past the panel 42 into which the tab is inserted. This may increase the stability of the joint. This joint keeps the rear panels in line with one another and provides a connection that prevents shear between the parts allowing the back panel to provide stability across the backs.
[0041] To provide stability to racking in both directions the direction of the tab 70 may be mirrored from top to bottom. That is to say that one tab 70 on a panel 50 may have an upper projecting portion and a lower recessed portion while another tab on the same panel has a lower projecting portion and an upper recessed portion. Adjacent panels 50 are formed with complementary tabs and fit together. Panels 50 on the side of a piece of furniture which do not have another adjoining panel 50 may be formed with a full tab as described in other figures. This allows a single panel to still give stability with out the other back panels being present.
[0042] FIG. 20 shows a top view of a piece of furniture with back panels 50 having tabs 70 . FIG. 21 shows a back view of the same piece of furniture. The back panels 50 can be used in a case construction or in the grid type constructions shown. A benefit to the multiple panels 50 is that it allows a large back panel to be broken into multiple smaller panels 50 . This can make packing and shipping easier.
[0043] Additionally patterns can be made with the back panels 50 by using panels of multiple colors, or using panels with different colors on each side. This allows the user to create patterns by selecting which side faces forward and how the panels 50 are arranged.
[0044] The back panels 50 shown in FIGS. 17 , 18 and 19 also illustrate how these panels may be applied to a shelving grid. 806 . The tabs 70 on the back panels 50 extend through slots 66 on the vertical panel 10 of a shelving grid. The recessed portion 70 A of a tab can accept the protruding portion 70 B of an adjoining tab 70 .
[0045] FIGS. 22 and 23 illustrate a method of captively connecting shelves or other divider panels 74 within adjoining panels 78 . The structure is similar to the method illustrated for back panels 50 and shows how this method can be applied to back panels, divider panels, shelves, etc. The shelf or partition 74 has protruding tabs 70 which, as discussed above, may be formed with a protruding portion and a recessed portion so that two adjoining tabs 70 from adjacent panels 74 nest together within a slot 66 . For stability, the tabs 70 may be mirrored on the same side of a partition 74 so that the perpendicular side edges of the tabs 70 abut the ends of slots 66 and prevent the partition 74 from moving in both directions in the slot 66 . The tabs 70 may be disposed in a complementary arrangement on the two opposite ends of the partition to allow two partitions/shelves 74 to enter a slot 66 from opposite sides. The angled design of the tabs 70 allows at least a portion of the tab to enter farther into the slot making it less likely to come out if there is some flexibility in the parts. It also can make assembly easier because parts are less likely to fall over then with a half depth straight tab.
[0046] As seen in FIG. 23 , furniture panels 78 which are on the ends of the furniture may be formed with blind slots 82 which are not cut all the way through the panel 78 . This provides a more appealing appearance to the furniture. Forming the tabs 70 so that they extends approximately three quarters of the way through a panel 78 provides sufficient engagement with a slot 66 while allowing for blind slots 82 which have a depth that is about three quarters of the thickness of the panel 78 or slightly greater to be used.
[0047] Flex Backs
[0048] FIGS. 24 and 25 illustrate a joint configuration that can be used in furniture to create a rigid piece of furniture, particularly in desks or other pieces for furniture with only a top for bottom but not both with legs that typically might be loose. The joint system includes a panel 86 with at least 3 tabs 90 . Two lower identical tabs 90 include a small recess on them, and an upper tab 90 that doesn't need a recess. A second panel 94 includes three corresponding slots 98 . The two lower slots 98 have a nub that when the panel 86 is inserted becomes snug with the recess in the tabs 90 . To insert the tabs 90 transversely into the slots 98 , the panel 86 must be flexed as the panel 86 must be disposed upward relative to panel 94 as shown in FIG. 24 so that the lower tabs 90 with recesses are not engaging the narrowed portion of the lower slots 98 . The upper slot 98 is enlarged and includes a lengthened upper portion which is disposed out of alignment with the lower two slots 98 . During assembly, the upper tab 90 is inserted transversely into the misaligned upper portion of the upper slot 98 while the lower tabs are inserted into the lower slots 98 , requiring the panel 86 to be bent.
[0049] The panel 86 is then pushed downward, causing the two lower tabs 90 to engage the narrowed lower portion of the two lower slots 98 . When the panel 86 has moved in a downward direction sufficiently far to engage the lower tabs 90 with the narrowed portion of the lower slots 98 , the upper tab 90 reaches a laterally enlarged portion of the upper slot 98 that allows the upper tab 90 to move laterally and relieve some of the bending which was required to place the 86 into initial engagement with the panel 94 . The panel 86 may maintain a small amount of bending in the assembled position shown in FIG. 26 . The upper tab 90 is engaged into the laterally extending portion of the upper slot 98 and this prevents the panel 86 from moving upwardly out of this position. The lower tabs 90 have a recessed portion on the lower side thereof which does not extend to the lateral side of the tabs and which engages to the narrowed portion of the lower slots 98 to prevent these tabs from being pulled transversely from the slots 98 . An advantage to this joint is the positive engagement the top slots give which make a much stronger joint especially for side to side racking. The back joint piece is best made from a thinner more flexible piece, which is advantageous for lighter weight and lower cost.
[0050] Door Joint
[0051] FIGS. 27 and 28 detail the door joint which may be used on furniture such as a cabinet portion of a bookshelf, a child's kitchen set, etc. This joint could also be used generally in a number of applications where it is desirable to create strong and durable door joint from planar materials with no hardware and minimal machining. This joint also minimizes pinching and thus protects little children's fingers from being pinched while playing. The door 102 is cut from a planar material with a hinge tab 106 protruding from the top and bottom edges adjacent a hinge edge of the door. A short tab 110 can be used at the bottom edge of the door away from the hinge to keep the door closed. A recess 114 may be formed into the back of the door that goes towards the centerline of the hinge tabs 106 to prevent pinching of fingers. A handle 118 may be formed as a hole in the door, a knob, etc. FIG. 28 is a top view of the door assembly. The top and bottom hinge tabs 106 are inserted into a hole 122 on a top and bottom plate 126 (i.e. a part of a cabinet or a play kitchen, etc.) The holes 122 may or may not extend all the way through the plate 126 . The door 102 can swing and pivots around the center of the hole 122 . A recess 130 accepts the nub 110 in the closed position and prevents it from opening without affirmative user effort. FIG. 29 is a cross section of the assembly.
[0052] Wave Form
[0053] FIG. 30 illustrates a grid unit such as a shelving unit as disclosed in the above figures which is made from flat planar pieces. The grid unit may be made of vertical panels 10 and horizontal panels 14 with slots 18 as discussed above. FIGS. 31A through 31H show the individual panels 301 through 208 used in the grid. Assembled together, they create a useful and aesthetically pleasing shelf. The front edges of the panels 10 , 14 are shaped with a wave in this illustration, though any number of shapes could be used including straight, jagged, or other.
[0054] By cutting the front edge of the panels 10 , 14 making shelving unit with a wave form the progressively moves across the individual panels, the illusion of a wavy surface is achieved across the front of the shelves. This can be quite aesthetically interesting and pleasing. The wave form (amplitude and frequency, as well as rate of advancement) may be the same for both horizontal and vertical members, which gives the illusion of a wave and trough passing over the shelving unit at a 45 degree angle. However, by varying the wavelength and advancement frequency between horizontal and vertical members, giving other angles. The waveform usually works when the wavelength is an integer multiple of the spacing between shelves (or slots). A longer wavelength is typically preferred, on the order of 1-2 times the overall shelf size to achieve an interesting visual surface.
[0055] Modularity of Units
[0056] The top and bottom edges as well as the back edges of the panels 10 , 14 which are outside panels in the grid may contain a hole 134 and associated edge recess 138 that can be used to connect adjoining units together into a larger furniture unit. The holes may be a number of shapes including square, round, slotted or other. The recess 138 on the edge can be used to allow the adjoining edges to butt into one another when being connected with appropriate connectors 142 shown in FIGS. 32 and 33 , for example. The interior pieces omit much of the detail to simplify and reduce manufacturing complexity, though all pieces could contain all features or greater functionality or all could omit features for simplicity.
[0057] FIG. 32 shows how two grid units may connect to each other on top of each other, or side by side to form, for example, a longer or taller shelving unit. Connectors 142 fit into the recess 138 and the holes 134 and connect the adjoining grids units. Multiple units can be connected in both directions. A wall anchor connector 146 is used to attach the grid unit to a wall by attaching to hole 134 , fitting into a recess 138 , and proving a flange and hole to allow the furniture to be attached to a wall. A wall connector 146 may include a front portion (i.e. a post 154 , body 166 , bridge post 158 ) which is the same as a connector 142 and a back portion which is angled and flat and has holes so screws can be used to connect it to a wall. Such a connector 146 can be used to attach a work surface to the top of a grid unit.
[0058] FIG. 33 illustrates how the grid units can be connect back to back by using connectors 142 inserted into the holes 134 and recesses 138 . This could be used to create a central room divider or freestanding shelving unit.
[0059] FIG. 34 illustrates a front view of several connected grid units. Each unit is shown by a dashed outline. Units could be made in squares or rectangles and of any multiple of dimensions. Straps 150 can be used to stabilize each individual unit, or the connected units
[0060] Connectors
[0061] FIGS. 35-37 illustrates a possible connector 142 used to connect grid units together. The connector 142 may include posts 154 that are inserted into the holes 134 . The connector may include a center bridge post 158 which fits into the recess 138 . A bridge plate 162 may be formed at the top of the bridge post 158 . A main plate 166 may attach the posts 154 and bridge post 158 into a single piece. The connector may be formed from a semi-rigid elastic material such as a thermoplastic. To assemble the parts, the main plate 166 may be flexed to bend the post 154 back and allow the post 154 and bridge post 158 to be inserted into a hole 134 and recess 138 on a furniture panel. The other side of the connector 142 is similarly attached to another furniture panel to attach the panels together. The furniture panels are held between the main plate 166 and bridge plate 162 and secured together by the post 154 and bridge post 158 .
[0062] FIG. 38 illustrates an alternative embodiment of the connector 142 . In this embodiment, the connector includes two opposed side plates 166 A which are each attached to a side post 154 and the bridge post 158 . The side plates 166 A are placed on opposite sides of the panels 10 , 14 which are assembled together and the panels are held between the side plates 166 A. FIG. 39 illustrates the alternative connector 142 of FIG. 38 installed and connecting two panels 170 together.
[0063] FIG. 40 illustrates another embodiment of the connector 142 which is similar to the connector of FIG. 38 but which includes elongate angled posts 154 . FIG. 41 illustrates two of the connectors 142 holding two planar pieces 170 together. The angled configuration of the posts 154 and holes 134 may improve the performance of the connector 142 in preventing the panels 170 from shifting back and forth relative to each other.
[0064] FIGS. 42 and 43 illustrate a cross section of a connector 142 used to attach panels 170 together. In discussing the connectors 142 , it is appreciated that the connectors 142 may be used to attach any of the various panels together. The side plates 166 A of the connector 142 may be flexed to allow the post 154 to be placed into the hole 134 to secure panels 170 together. The connector 142 may then bend back to the unbent position shown in FIG. 43 to connect the panels 170 .
[0065] FIG. 44 shows another connector 142 which may be used to connect panels 170 together. The connector is formed of two pieces which are assembled together to hold panels 170 together. The connector 142 may have two halves 174 which are passes through the hole 134 in the panels 170 and the halves 174 are then fastened together to join the connector 142 and secure the panels 170 . The connector halves 174 may be fastened together with screws 178 . The connector half 174 may have a hollow post 182 which fits through a hole 134 and a smaller post 186 which fits into a recess in the hollow post 182 . A connector half 174 may have a hollow post 182 and a smaller post 186 which pass through holes 134 in two panels 170 and engage a hollow post 182 and smaller post 186 on another connector half. FIG. 45 shows another connector 142 which is similar to the connector of FIG. 44 . The connector may have a snap-together connection where each half 174 of the connector has arms 190 which pass through the hole 134 and a receptacle 194 which receives these arms. Each connector half 174 may be placed so that the arms 190 extend through a hole 134 in a panel 170 and the receptacle 194 is aligned with a hole 134 in an adjacent panel 170 . Another connector half 174 is similarly situated so that the arms 190 of each connector half 174 engage the receptacle 194 of the other connector half. The arms 190 have ridges or other projections which engage the receptacles 194 and lock the connector halves 174 together to fasten the panels 170 together. The arms 190 may be pressed together to release the arms from the receptacle 194 and remove the connector 142 as desired. The two connector pieces may be designed so that one end has a male end and the other ends is female end. This allows for lower tooling costs and few parts.
[0066] Interchangeable Components
[0067] There are several considerations that can be given to optimize the use, manufacture, and shipping of grid components. The grid components can be optimized for modularity. The design of the wave shaped front of the shelving grids can be modified to allow units to be joined together in modular units. FIG. 46 illustrates how to achieve this. If the modular units are designed so that the neutral portion 198 of the wave shaped front (the average forward distance of the trough 202 and crest 206 , see FIGS. 30 and 33 for example) lies diagonally across the center of a square shelf, the shelf can be made from four smaller shelf sections, all of which are made of the same parts. FIG. 47 shows that the four sections (A and A- 1 ) would each be made of the same parts, but sections A would be constructed in the same way, and sections A- 1 would be constructed in reverse order. This allows greater flexibility in assembling the shelve sections with fewer unique parts.
[0068] For modularity, the panels making the grids should be extended to the mid-point of the cubby areas between the panels. To allow flexibility in modularity for a 2×2 cubby, the top/bottom edge could be cut short. For a cubby intended to be stacked on one another in most cases, the top and bottom portions could be reduced to for less material usage and better aesthetic.
[0069] Optimized for Fewer Components
[0070] FIG. 48 shows another embodiment of the shelves. In this embodiment, the crest 206 crosses centered between joints of panels 10 and panels 14 rather than directly over the joints between panels 10 , 14 . This allows the entire shelf to be built from four unique parts, (C, C- 1 , D, and D- 1 ) though the direction of the parts is alternated. This also allows for design with fewer parts. These principles can also be applied to non-sinusoidal, but repeating wave like forms. Some of the methods may require a wave form that is symmetric about the trough and peak but not all do.
[0071] Back Stabilization
[0072] FIG. 49 shows how slots or holes 210 can be used to allow straps or cords 214 to be attached diagonally between the corners of furniture panels 218 (which may be panels 10 , 14 , 42 , 46 , etc.) for stability. FIG. 50 shows an alternate configuration where a panel 218 is formed with a tab 222 at an edge thereof, such as at a back edge of the panel 218 . The tab 222 may be formed by slots 226 which converge inwardly so that the outside edge of the tab 222 is wider than the root of the tab, causing a looped cord under tension to be held at the root of the tab 222 . FIGS. 50 A and 50 B show alternative methods of attaching a cord to the panel. A cord 214 may be placed across a diagonal of a piece of furniture as shown in FIG. 49 to stabilize the furniture. The cord 214 may have loops 230 formed on its ends and the loops 230 may be placed over tabs 222 to secure the cord to the furniture. FIG. 51 shows a tensioning device 234 may be used to apply tension to the cord 214 after placement on the tabs 222 . The tensioning device 234 may include two holes 238 through which the cord 214 passes and a hook 242 which is secured around the cord 214 to apply tension. FIG. 52 shows the tension device 234 and cord 214 in a non-tensioned configuration. The cord 214 passes through the holes 238 . FIG. 53 shows the tension device 234 and cord in a tensioned configuration. The tensioning device 234 has been rotated to place the hook 242 around the end of the cord 214 which passes into the hole 238 farthest away from the hook 242 . This causes the cord 214 to double back over itself and shortens the cord 214 , applying tension to the cord 214 as placed between tabs 222 .
[0073] If desired, only one cord needs a tensioner 234 . If this is done, though, the cord with no tensioner needs to be shorter, and when under load, the shorter cord and the longer cord with the tensioner 234 secured need to be the same length. One advantage to the tabs 222 and cord 214 is that they take up very little of the cubby space as they are right on the back of the panels.
[0074] Alternate Grid System
[0075] FIGS. 54 through 57 illustrate cross sectional views of a joint and a connector which allows the shelving grid of panels 10 , 14 to be constructed without tabs or edges which extend beyond the Grid. Rather than having slots 18 as used in the middle of the shelving grid, the perimeter joints around the grid may be formed with connectors 142 . The adjoining edges of panels 10 and 14 may be formed with holes 134 and recesses 138 as shown in FIG. 30 . The connector may have posts 154 and a central bridge post 158 with body plates 166 and bridge plates 162 disposed on opposite sides of the panels 10 , 14 . Rather than being relatively flat for joining in-plane panels 10 , 14 , the connectors may be formed in cross, Tee, and angle configurations for joining panels 10 , 14 at corners, tees, and crosses. The connectors are similar to the connectors shown in FIGS. 30-43 if these had been cut through at the center and joined together in the configurations shown. These angled connectors 142 in FIGS. 54 and 55 allow a shelving grid to be formed without overhanging tabs or edges. The connectors shown in FIGS. 56 and 57 may be used to connect sections of shelving grid together to form a larger shelving grid.
[0076] Bins
[0077] Storage bins or boxes can be used with a shelving grid or cubby system. There are several ways that bins can be used to create visually interesting and functional storage.
[0078] City Scape Buildable Bins
[0079] FIG. 58 illustrates a large shelving grid or cubby unit referred to generally at 246 . This unit 246 has a number of shelf areas or cubbies formed from panels 10 , 14 as discussed previously. The unit 246 may be formed from a large shelving grid or multiple smaller shelving grids connected together. Insertable subdividers 250 and 254 have been inserted into some of the cubby openings. The insertable subdividers 250 , 254 may also use the joints described previously in discussing panels 10 , 14 and slots 18 . Storage bins 258 may be inserted into the cubbies as desired. These storage bins may be boxes made of cardboard or plastic. The bins 258 may be printed with a variety of designs.
[0080] In one embodiment, some of the bins 258 are made to look like the facade of buildings. These bins are arranged to look like a skyline. Bin 262 is printed to represents a garage. Other bins that represent shops, apartments, labs, and other common buildings could be included. These building bins can be arranged to look like different cityscapes. In another embodiment, the bins are made to look like common household appliances, so the grid units can become a play kitchen. Printed bins become fun and interesting objects to children and are more decorative than ordinary bins.
[0081] Modular building bins 258 as well as bins 266 which are unprinted or printed to look like sky prints are illustrated in FIGS. 59 through 61 . Existing building have been identified and simplified to find repeating block sections that could be repeated to represent a building. These block sections are then printed on multiple bins, the bins are then put in the shelving units and the adjoining portions form the outline of a building. Multiple stacks next to each other can form an image similar to a city skyline. The tops may be unique to make a building more identifiable. Bins printed like smaller buildings may be included to create a layered effect. These bins may be printed front, back, and side with different patterns if desired.
[0082] FIG. 62 illustrates bins 270 which are printed to look like parts of a house. These bins may be arranged to create different houses similar to how the city bins can be rearranged. FIGS. 63 and 64 show bins 274 which are printed to look like block elements of a video game. These bins 274 may be arranged to create different video game levels. Printed bins such as these allow a user to create custom decorative appearances for what would otherwise be a less attractive wall of storage boxes.
[0083] Patterned Bins
[0084] FIGS. 65 through 67 show bins 278 which are printed to show morphing patterns. The bins 278 are shown as the flat pattern of a box that is die cut and folded into box. When folded, the bin 278 has a front pattern 282 and a different back pattern 286 , and side patterns 290 which gradually morph between the front and back patterns.
[0085] FIGS. 68 and 69 show how the pattern bins 278 may be placed in a shelving grid or cubby shelf to achieve various visual effects. The layout of the patterns and the morph allows a large number of interesting combinations. By only exposing the front or back patterns two very different patterns are given. By showing the sides, gradual transitions can be made. The bins can be arranged as desired by a user to create different visual patterns to make a storage shelving unit more attractive.
[0086] To create a morphing pattern, the pattern height typically needs to be the same, though the width can vary. Other mediums besides printing could also be sued such as molding or stitching. The patterns may also morph between different colors, etc.
[0087] FIGS. 70 and 71 show two different ways for doing morphing prints on bins. These figures show top views of bins to illustrate how the patterns may change around the different sides of the bins. FIG. 70 shows a pattern on the front and a different pattern on the back with both sides having a pattern which morphs or transitions between the front and back patterns. FIG. 71 illustrates a bin which has a first pattern on a corner of the bin and a second different pattern on an opposite corner of the bin and all four sides morph or transition between the two patterns. The bin could start at one corner then morph to another print on the opposite corner, then morph back as one views successive sides around the bin.
[0088] The above description of illustrated examples of the present invention, including what is described in the Abstract, are not intended to be exhaustive or to be limitation to the precise forms disclosed. While specific examples of the invention are described herein for illustrative purposes, various equivalent modifications are possible without departing from the broader scope of the present claims. Indeed, it is appreciated that specific example dimensions, materials, voltages, currents, frequencies, power range values, times, etc., are provided for explanation purposes and that other values may also be employed in other examples in accordance with the teachings of the present invention.
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Modular furniture is provided. The modular furniture includes joint and furniture components which allow the furniture to be assembled without tools and which provide increased stability and strength to the furniture. The modular furniture also provides increased attractiveness and user customization while using a limited number of different components.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application claims benefit to and is a continuation of U.S. patent application Ser. No. 11/283,518, filed on Nov. 17, 2005 now U.S. Pat. No. 7,508,608, which claims the benefit of U.S. Provisional Patent Application No. 60/629,093, filed Nov. 17, 2004, both of which are hereby incorporated by reference in their entirety.
The following cases contain subject matter related to that disclosed herein and are incorporated herein by reference in their entirety: U.S. patent application Ser. No. 10/661,234, filed Sep. 12, 2003, entitled “Diffraction Grating-Based Optical Identification Element”; U.S. patent application Ser. No. 10/661,031 filed Sep. 12, 2003, entitled “Diffraction Grating-Based Encoded Micro-particles for Multiplexed Experiments”; U.S. patent application Ser. No. 10/661,082, filed Sep. 12, 2003, entitled “Method and Apparatus for Labeling Using Diffraction Grating-Based Encoded Optical Identification Elements”; U.S. patent application Ser. No. 10/661,115, filed Sep. 12, 2003, entitled “Assay Stick”; U.S. patent application Ser. No. 10/661,836, filed Sep. 12, 2003, entitled “Method and Apparatus for Aligning Microbeads in order to Interrogate the Same”; U.S. patent application Ser. No. 10/661,254, filed Sep. 12, 2003, entitled “Chemical Synthesis Using Diffraction Grating-based Encoded Optical Elements”; U.S. patent application Ser. No. 10/661,116, filed Sep. 12, 2003, entitled “Method of Manufacturing of a Diffraction grating-based identification Element”; and U.S. patent application Ser. No. 10/763,995, filed Jan. 22, 2004, entitled, “Hybrid Random Bead/Chip Based Microarray”, U.S. Provisional Patent Application Ser. Nos. 60/609,583, 60/610,059 and 60/609,712, all filed Sep. 13, 2004; U.S. Provisional Patent Application Ser. Nos. 60/611,205, 60/610,910, 60/610,833, 60/610,829, 60/610,928, all filed Sep. 17, 2004; U.S. Provisional Patent Application Ser. No. 60/611,676, filed Sep. 20, 2004; and U.S. patent application Ser. No. 10/956,791, filed Oct. 1, 2004.
BACKGROUND OF INVENTION
Technical Field
The present invention relates to a method and apparatus for fabricating an optical identification element; and more particularly to a method and apparatus for fabricating a holographic optical identification element using a lithographic technique, as well as the holographic optical identification element itself.
SUMMARY OF INVENTION
The present invention provides a new and unique method for fabricating an optical identification element, wherein a removable plate or substrate having a photosensitive material fabricated on is provided, one or more gratings are written on the photosensitive material, then lines are etched to create one or more separate optical identification elements.
The one or more gratings may be written by exposing the photosensitive material to ultraviolet (UV) light.
The lines may be etched to create the one or more separate optical identification elements by photolithography to define/create the same.
The one or more separate optical identification element are planar elements.
The optical identification element may take the form of a holographic optical identification element having one of the following geometric shapes, such as a plate, a bar, a brick, a disc, a slab, etc.
The method according to the present invention enables many possible options, geometries, sizes, photosensitive materials in relation to the overall fabrication of an optical identification element.
The present invention also includes the possibly of using a surface relief grating, a densification grating, cover slips, or borosilicate.
The scope of the invention is also intended to include the apparatus for fabricating an optical identification element consistent with the description of the aforementioned method, including a combination of devices for performing the steps described above, as well as an optical identification element that results from the steps of the method or process shown and described herein.
One advantage of the present invention is that conventional technology may be used to fabricate an optical identification element with a high level of flexibility.
In effect, the present invention potentially adds a whole new dimension to existing biochip technology.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing, which is not drawn to scale, includes the following:
FIG. 1 is a diagram of steps for fabricating a optical identification element according to the present invention.
FIG. 2 is a diagram of a partially etched substrate according to the present invention.
FIG. 3 is a block diagram of an optical arrangement for fabricating an optical identification element according to the present invention.
FIG. 4 is a diagram of an optical identification element according to the present invention.
FIG. 5 is a side view of an optical identification element.
FIG. 6 is a perspective view of an optical identification element having a grating that is smaller than the substrate.
FIGS. 7( a )-( c ) show images of digital codes on a CCD camera.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows steps 1 - 4 for performing a method for fabricating an optical identification element 20 (see also FIG. 4 ) according to the present invention.
In step 1 , a removable plate or substrate 10 having a photosensitive material 10 fabricated thereon. Suitable photosensitive materials are known in the art, and the scope of the invention is not intended to be limited to any particular kind either now known or later developed in the future. The plate or substrate 10 may take the form of many different medium or material, including, but not limited to, an optical medium or material, although the scope of the invention is also intended to include other materials for the substrate now known or later developed in the future.
In step 2 , one or more gratings 13 (best shown in FIGS. 2 and 4 ) are written on the photosensitive material 12 , for example, by exposing the photosensitive material 12 to ultraviolet (UV) light 14 , although the scope of the invention is also intended to include using other grating writing techniques either now known or later developed in the future.
In step 3 , one or more lines 16 are etched or formed to create and form one or more separate optical identification elements that are generally indicated as 18 in FIG. 1 using photolithography to define/create the same, although the scope of the invention is also intended to include using other etching techniques either now known or later developed in the future.
In step 4 , the etching process in step 3 results in the formation of the one or more separate optical identification elements 20 . In this case, the elements 18 are removed or separated from the substrate 10 by the etching process. Alternatively, the elements 18 may be removed or separated from the substrate 10 by exposing them in a suitable solution and form the one or more optical identification elements 20 . Such a suitable solution is known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof. The one or more separate optical identification element 20 take the form of planar elements, as distinguished from optical fiber, optical filaments, or the like that are known in the art.
Moreover, the scope of the invention is intended to include the optical identification element 20 taking the form of a holographic optical identification element or other suitable optical identification element having an interference pattern reproduced from a pattern of interference produced by a split coherent beam of radiation (as a laser) either now known or later developed in the future, or by any of the techniques described in U.S. patent application Ser. No. 10/661,234 or U.S. patent application Ser. No. 10/661,116, and other related cases referenced herein. Moreover, the optical identification elements 20 may take the geometric form of one or more planar objects, including plates, bars, bricks, discs, slabs, chips, or other suitable planar geometric shape and/or dimensionality now known or later developed in the future, including those described in U.S. patent application Ser. No. 10/661,234 and other patent applications referenced herein.
Alternative Technique
The present invention also provides an alternative format micro “chip” assay technique relating to code reading via embedded collocated gratings, as follows:
Grating Orientation:
The scope of the invention is intended to include at least the following grating orientation techniques shown by way of example in FIG. 2 :
1) Writing grating codes 13 a , 13 b , 13 c , 13 d 1 , 13 d 2 at multiple axes across each disc or element 18 —where a single axis reader always may be used to pick up one code.
2) Adding orientation ‘marker’ 15 to one or more discs or elements 18 , such as by adding one or more of the following:
a) Magnetic material for self-alignment; b) Birefringence; or c) Fluorescence to determine alignment/orientation.
3). Putting each “bit” in along a different axis and use a spinning readout system (e.g. each bit assessed).
The Optical Arrangement or Apparatus
The scope of the invention is also intended to include an optical arrangement or apparatus for fabricating an optical identification element consistent with the description of the aforementioned method, including a combination of devices for performing the steps described above. For example, FIG. 3 shows the optical arrangement or apparatus generally indicated as 30 for fabricating such an optical identification element 20 , including the combination of a means or device 32 for providing a removable plate or substrate 10 having the photosensitive material 12 fabricated thereon; a means or device 34 for writing one or more gratings 13 , 13 a , 13 b , 13 c , 13 d 1 , 13 d 2 (see FIG. 2 ) on the photosensitive material 12 ; and a means or device 36 for separating and creating the one or more separate optical identification elements 20 , including by, e.g., etching the lines 16 on the photosensitive material 12 .
The Optical Identification Element 20
FIG. 4 shows, by way of example, the optical identification element 20 in greater detail that results from the steps of the method or process shown in FIG. 1 , and/or the optical arrangement shown in FIG. 3 . The scope of the invention is also intended to include the optical identification element itself made by the method or process set forth above, including, but not limited to, a holographic optical identification element made from the lithographic technique described herein. The present invention may be used to create the encoded elements consistent with that described in copending U.S. patent application Ser. No. 10/661,234, filed 12 Sep. 2003 and the other patent applications referenced herein, which are incorporated herein by reference in their entirety.
Referring to FIG. 5 , an optical identification element 8 comprises a known optical substrate 110 , having an optical diffraction grating 112 disposed (or written, impressed, embedded, imprinted, etched, grown, deposited or otherwise formed) in the volume of or on a surface of a substrate 110 . The grating 112 is a periodic or aperiodic variation in the effective refractive index and/or effective optical absorption of at least a portion of the substrate 110 .
The substrate 110 has an inner region 120 where the grating 112 is located. The inner region may be photosensitive to allow the writing or impressing of the grating 112 . The substrate 110 has an outer region 118 which does not have the grating 112 therein.
The grating 112 is a combination of one or more individual spatial periodic sinusoidal variations in the refractive index that are collocated along the length of the grating region 120 of the substrate 110 , each having a spatial period (or pitch) Λ. The grating 112 (or a combination of gratings) represents a unique optically readable code, made up of bits. In one embodiment, a bit corresponds to a unique pitch Λ within the grating 112 .
The grating 112 may also be referred to herein as a composite or collocated grating. Also, the grating 112 may be referred to as a “hologram”, as the grating 112 transforms, translates, or filters an input optical signal to a predetermined desired optical output pattern or signal.
The substrate 110 comprises silica glass (SiO 2 ) having the appropriate chemical composition to allow the grating 112 to be disposed therein or thereon. Other materials for the optical substrate 110 may be used if desired. For example, the substrate 110 may be made of any glass, e.g., silica, phosphate glass, borosilicate glass or other glasses, or made of glass and plastic, or solely plastic. For high temperature or harsh chemical applications, the optical substrate 110 made of a glass material is desirable. If a flexible substrate is needed, a plastic, rubber or polymer-based substrate may be used. The optical substrate 110 may be any material capable of having the grating 112 disposed in the grating region 120 and that allows light to pass through it to allow the code to be optically read.
The optical substrate 110 with the grating 112 has a length L and an outer diameter D 1 , and the inner region 120 diameter D. The length L can range from very small (about 1-1000 microns or smaller) to large (about 1.0-1000 mm or greater). In addition, the outer dimension D 1 can range from small (less than 1000 microns) to large (1.0-1000 mm and greater). Other dimensions and lengths for the substrate 110 and the grating 112 may be used.
The grating 112 may have a length Lg of about the length L of the substrate 110 . Alternatively, the length Lg of the grating 112 may be shorter than the total length L of the substrate 110 .
Moreover, referring to FIG. 6 , the size of any given dimension for the region 120 of the grating 112 may be less than any corresponding dimension of the substrate 110 . For example, if the grating 112 has dimensions of length Lg, depth Dg, and width Wg, and the substrate 110 has dimensions of length L, depth D, and width W, the dimensions of the grating 112 may be less than that of the substrate 110 . Thus, the grating 112 , may be embedded within or part of a much larger substrate 110 . Instead of rectangular dimensions or coordinates for size of the substrate 110 , the element 8 , or the grating 112 , other dimensions/coordinates for size may be used, e.g., polar or vector dimensions.
Also, the element 8 may be embedded or formed in or on a larger object for identification of the object.
The substrate 110 may have end-view cross-sectional shapes other than circular, such as square, rectangular, elliptical, clam-shell, D-shaped, or other shapes, and may have side-view sectional shapes other than rectangular, such as circular, square, elliptical, clam-shell, D-shaped, or other shapes. Also, 3D geometries other than a cylinder may be used, such as a sphere, a cube, a pyramid, a bar, a slab, a plate, a brick, or a disc shape, or any other 3D shape. Alternatively, the substrate 110 may have a geometry that is a combination of one or more of the foregoing shapes.
The dimensions, geometries, materials, and material properties of the substrate 110 are selected such that the desired optical and material properties are met for a given application. The resolution and range for the optical codes are scalable by controlling these parameters (discussed more hereinafter).
The substrate 110 may be coated with a polymer material or other material that may be dissimilar to the material of the substrate 110 , provided that the coating on at least a portion of the substrate, allows sufficient light to pass transversely through the substrate for adequate optical detection of the code using side illumination.
Referring to FIG. 7 , illustrations ( a )-( c ), for the grating 112 in a cylindrical substrate 110 having a sample spectral 17 bit code (i.e., 17 different pitches Λ 1 -Λ 17 ), the corresponding image on a CCD (Charge Coupled Device) camera is shown for a digital pattern of 17 bit locations 89 . FIG. 7( b ), ( c ), and ( a ), respectively, illustrate 7 bits turned on (10110010001001001); 9 bits turned on (11000101010100111); and all 17 bits turned on (11111111111111111).
For the images in FIG. 7 , the length of the substrate 110 was 450 microns, the outer diameter D 1 was 65 microns, the inner diameter D was 14 microns, δn for the grating 112 was about 10 −4 , n 1 in portion 120 was about 1.458 (at a wavelength of about 1550 nm), n 2 in portion 118 was about 1.453, the average pitch spacing Λ for the grating 112 was about 0.542 microns, and the spacing between pitches ΔΛ was about 0.36% of the adjacent pitches Λ.
The grating 112 may be impressed in the substrate 110 by any technique for writing, impressed, embedded, imprinted, or otherwise forming a diffraction grating in the volume of or on a surface of a substrate 110 . Examples of some known techniques are described in U.S. Pat. Nos. 4,725,110 and 4,807,950, entitled “Method for Impressing Gratings Within Fiber Optics”, to Glenn et al; and U.S. Pat. No. 5,388,173, entitled “Method and Apparatus for Forming A periodic Gratings in Optical Fibers”, to Glenn, respectively, and U.S. Pat. No. 5,367,588, entitled “Method of Fabricating Bragg Gratings Using a Silica Glass Phase Grating Mask and Mask Used by Same”, to Hill, and U.S. Pat. No. 3,916,182, entitled “Periodic Dielectric Waveguide Filter”, Dabby et al, and U.S. Pat. No. 3,891,302, entitled “Method of Filtering Modes in Optical Waveguides”, to Dabby et al, which are all incorporated herein by reference to the extent necessary to understand the present invention.
Alternatively, instead of the grating 112 being impressed within the substrate material, the grating 112 may be partially or totally created by etching or otherwise altering the outer surface geometry of the substrate to create a corrugated or varying surface geometry of the substrate, such as is described in U.S. Pat. No. 3,891,302, entitled “Method of Filtering Modes in Optical Waveguides”, to Dabby et al, which is incorporated herein by reference to the extent necessary to understand the present invention, provided the resultant optical refractive profile for the desired code is created.
Further, alternatively, the grating 112 may be made by depositing dielectric layers onto the substrate, similar to the way a known thin film filter is created, so as to create the desired resultant optical refractive profile for the desired code.
Unless otherwise specifically stated herein, the term “microbead” is used herein as a label and does not restrict any embodiment or application of the present invention to certain dimensions, materials and/or geometries.
Applications, Uses, Geometries and Embodiments for the Encoded Element of the Present Invention
Applications, uses, geometries and embodiments for the encoded element of the present invention may be the' same as that described in the following cases which are all incorporated herein by reference in their entirety: U.S. patent application Ser. No. 10/661,234, filed Sep. 12, 2003, entitled “Diffraction Grating-Based Optical Identification Element”; U.S. patent application Ser. No. 10/661,031 filed Sep. 12, 2003, entitled “Diffraction Grating-Based Encoded Microparticles for Multiplexed Experiments”; U.S. patent application Ser. No. 10/661,082, filed Sep. 12, 2003, entitled “Method and Apparatus for Labeling Using Diffraction Grating-Based Encoded Optical Identification Elements”; U.S. patent application Ser. No. 10/661,115, filed Sep. 12, 2003, entitled “Assay Stick”; U.S. patent application Ser. No. 10/661,836, filed Sep. 12, 2003, entitled “Method and Apparatus for Aligning Microbeads in order to Interrogate the Same”; U.S. patent application Ser. No. 10/661,254, filed Sep. 12, 2003, entitled “Chemical Synthesis Using Diffraction Grating-based Encoded Optical Elements”; U.S. patent application Ser. No. 10/661,116, filed Sep. 12, 2003, entitled “Method of Manufacturing of a Diffraction grating-based identification Element”; and U.S. patent application Ser. No. 10/763,995, filed Jan. 22, 2004, entitled, “Hybrid Random Bead/Chip Based Microarray”, U.S. Provisional Patent Application Ser. Nos. 60/609,583, 60/610,059 and 60/609,712, all filed Sep. 13, 2004; U.S. Provisional Patent Application Ser. Nos. 60/611,205, 60/610,910, 60/610,833, 60/610,829, 60/610,928, all filed Sep. 17, 2004; U.S. Provisional Patent Application Ser. No. 60/611,676, filed Sep. 20, 2004; and U.S. patent application Ser. No. 10/956,791, filed Oct. 1, 2004.
Computer Programs and Other Data Processing Methods
Various aspects of the present invention may be conducted in an automated or semi-automated manner, generally with the assistance of well-known data processing methods. Computer programs and other data processing methods well known in the art may be used to store information including e.g. microbead identifiers, probe sequence information, sample information, and binding signal intensities. Data processing methods well known in the art may be used to read input data covering the desired characteristics.
Applications
The invention may be used in many areas such as drug discovery, functionalized substrates, biology, proteomics, combinatorial chemistry, DNA analysis/tracking/sorting/tagging, as well as tagging of molecules, biological particles, matrix support materials, immunoassays, receptor binding assays, scintillation proximity assays, radioactive or nonradioactive proximity assays, and other assays, (including fluorescent, mass spectroscopy), high throughput drug/genorne screening, and/or massively parallel assay applications. The invention provides uniquely identifiable beads with reaction supports by active coatings for reaction tracking to perform multiplexed experiments.
SCOPE OF THE INVENTION
The dimensions and/or geometries for any of the embodiments described herein are merely for illustrative purposes and, as such, any other dimensions and/or geometries may be used if desired, depending on the application, size, performance, manufacturing requirements, or other factors, in view of the teachings herein.
It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein. Also, the drawings herein are not drawn to scale.
Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.
Moreover, the invention comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth.
It will thus be seen that the objects set forth above, and those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.
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A method for fabricating microparticles. The method includes providing a removable substrate that has a photosensitive material. The substrate has a plurality of inner regions. Each inner region surrounds a corresponding outer region. The method also includes providing at least one optically detectable code within at least one of the inner regions of the substrate and etching lines into the substrate to create a plurality of microparticles having at least one optically detectable code therein. The microparticles have elongated bodies that extend in an axial direction. The optically detectable codes extend in the axial direction within the microparticles.
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[0001] The invention relates to an improved undulating diaphragm pump.
BACKGROUND OF THE INVENTION
[0002] Pumps are known, e.g. from document FR 2 744 769, that have a diaphragm mounted in a propulsion chamber so as to undulate under drive from at least one linear electromagnetic actuator between two end plates that define a chamber for propelling fluid from an inlet of the pump towards an outlet of the pump.
[0003] The movable portion of the actuator is generally directly coupled to an outer edge of the diaphragm extending beside the inlet of the propulsion chamber and it imparts transverse oscillation to the outer edge of the diaphragm, thereby causing the diaphragm to undulate perpendicularly to its plane. The effect of coupling between the undulations and the fluid is to propel the fluid from the inlet towards the outlet of the propulsion chamber.
[0004] In general, the flow section for fluid in the propulsion chamber decreases from the inlet of the propulsion chamber towards the outlet of the pump, thus giving rise, because of flow rate conservation, to an acceleration of the fluid and thus to an increase in the mean speed of the fluid as measured in each cross-section of the propulsion chamber, which speed increases progressively from the inlet towards the outlet of the propulsion chamber.
OBJECT OF THE INVENTION
[0005] The invention seeks to propose a diaphragm pump that makes greater efficiency possible.
BRIEF DESCRIPTION OF THE INVENTION
[0006] In order to achieve this object, the invention provides an undulating diaphragm pump having a propulsion chamber for receiving said diaphragm, the diaphragm having mechanical characteristics that vary from an inlet of the propulsion chamber towards an outlet of the propulsion chamber in such a manner that when the diaphragm is actuated to deform with a traveling wave that propagates from the inlet towards the outlet of the propulsion chamber in order to propel the fluid, the propagation speed of the wave in the diaphragm in any cross-section relative to the movement of the fluid inside the propulsion chamber is equal to or greater than the mean travel speed of the fluid in said section.
[0007] This ensures that the diaphragm wave advances at all points in the propulsion chamber at a speed that is faster than that of the fluid it is propelling, and that the diaphragm transmits its mechanical energy to the fluid over the entire propagation length of the wave along the diaphragm. The coupling between the undulating diaphragm and the fluid is thus optimized, with the movement of the diaphragm being more efficient, since the entire surface area of the diaphragm is propulsive, thereby improving the efficiency of the pump.
[0008] It is thus possible to increase the speed of the fluid at the outlet from the propulsion chamber and to obtain relatively large flow rates, making it possible to decrease the diameter of the diaphragm and the overall size of the pump head. In addition, this makes it possible to avoid any positive transfer of energy from the fluid to the diaphragm which would run the risk of causing the diaphragm to come into contact with the end plates. Such contacts give rise to noise and run the risk of damaging the diaphragm. It is also possible to reduce the pulsations in the pressure and in the flow rate at the outlet from the propulsion chamber.
[0009] In a particular embodiment of the invention, the diaphragm has imparted thereto stiffness that varies and that increases going from the inlet towards the outlet of the propulsion chamber. It is known that stiffness is an important parameter for determining the propagation speed of the traveling wave that deforms the diaphragm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention can be better understood in the light of the accompanying drawings, in which:
[0011] FIG. 1 is a diagrammatic half-view in section of an undulating diaphragm pump of the invention;
[0012] FIG. 2 is a partially cut-away perspective view of a disk-shaped diaphragm in various particular embodiments of the invention;
[0013] FIG. 3 is a section view of an undulating diaphragm pump fitted with a diaphragm having a neck in another particular embodiment of the invention; and
[0014] FIGS. 4 , 5 , 6 , 7 , and 8 are perspective views of diaphragms in other particular embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] With reference to FIG. 1 , the undulating diaphragm pump of the invention comprises a diaphragm that extends between two end plates 2 that constitute a fluid propulsion chamber. An actuator (not shown) is connected to an edge 3 of the diaphragm and actuates the edge 3 of the diaphragm transversely so as to cause the diaphragm to undulate with a traveling wave that propagates from the edge 3 towards the center 4 of the diaphragm. Fluid is thus transferred between the two end plates from an inlet of the propulsion chamber at the periphery thereof towards an outlet of the propulsion chamber situated at the center thereof.
[0016] If Z is the axis of revolution of the pump, and if the pump is notionally sectioned on a circular cylinder about the axis Z, it can be seen that the portion of the cylinder that is situated between the end plates 2 defines a working section for passing the fluid, ignoring the section of the diaphragm intersected by the cylinder. Naturally, on coming closer to the center of the diaphragm, the area of the working section decreases because of the decrease in the radius of the cylinder, and also because the two end plates come closer together. For an incompressible fluid such as a liquid, the law of flow rate conservation between the inlet and the outlet of the propulsion chamber causes the mean flow speed of the fluid through the various working sections to increase in proportion to the decrease in the area of the working section.
[0017] The invention seeks to propose a diaphragm that takes account of this variation in the mean speed of the fluid between the inlet and the outlet of the fluid propulsion chamber.
[0018] With reference to FIG. 1 , the fluid flow sections lie between the diaphragm and the end plates, and the crests of the waves form constrictions in section that advance at the propagation speed of the wave. The pressure difference between the pressure P 1 upstream from a constriction and the pressure P 2 downstream from the constriction depends on the speed difference between the propagation speed of the wave and the mean speed of the fluid. The product of this pressure difference (P1−P2) multiplied by the mean flow rate in said section corresponds to the hydraulic power that is locally transmitted to the fluid.
[0019] Maintaining a positive speed difference throughout the cross-section of the propulsion chamber makes it possible to guarantee positive power transmission to the fluid over the entire propagation length of the wave along the diaphragm, i.e. over the entire active radius of the diaphragm in this example.
[0020] Thus, wave conditions establish a series of constrictions and pressure differences that extend from the inlet pressure to the outlet pressure of the propulsion chamber. The difference between the inlet pressure and the outlet pressure multiplied by the mean flow rate corresponds to the mean hydraulic power transmitted to the fluid. In this example it is ensured that the diaphragm transmits its mechanical energy to the fluid over its entire active radius, with a traveling wave in the diaphragm propagating throughout the cross-section of the propulsion chamber at a speed that is faster than the speed with which the fluid travels through said section of the propulsion chamber.
[0021] In the particular embodiment given reference A in FIG. 2 , the diaphragm 1 is made up for this purpose of concentric annular portions that are made of materials that have different moduluses of elasticity and that are disposed in such a manner that the modulus of elasticity E of the material of the diaphragm increases from the peripheral edge 3 of the diaphragm going towards the center 4 of the diaphragm more quickly than the thickness h of the diaphragm decreases. The variation in the modulus of elasticity E is represented symbolically by a succession of annular zones, naturally constituted in the detail view solely by their sections in the section plane. Thus, the product Exh measured in a cross-section increases continuously going from the edge 3 towards the center 4 so that the propagation speed of the traveling wave that deforms the diaphragm 1 in operation increases continuously.
[0022] In FIG. 2 , it can be seen that the cylinder of radius R 1 defines a working flow section S 1 (of circular cylindrical shape) for the fluid and that the cylinder of radius R 2 defines a working flow section S 2 (likewise of circularly cylindrical shape) for the fluid, the areas of these two sections being in the ratio (R2/R1) 2 ×h2/h1, where h 1 and h 2 are the heights between the end plates at the sections S 1 and S 2 respectively. The area of the section S 2 is thus considerably smaller than the area of the section S 1 , and the speed of the fluid in the section S 2 is thus greater than the speed of the fluid in the section S 1 .
[0023] It is appropriate to ensure that the variation in the product Exh, which is one of the important parameters determining the propagation speed of the traveling wave that deforms the diaphragm, varies sufficiently quickly to ensure that the propagation speed is always higher than the mean speed of the fluid, or indeed increases faster than the speed of the fluid on approaching the center of the propulsion chamber.
[0024] If this condition is satisfied, then the diaphragm transmits its mechanical energy to the fluid over the entire propagation length of the wave along the diaphragm, i.e. along the entire active radius of the diaphragm.
[0025] With reference to the embodiment referenced B, the diaphragm 11 is made out of two materials: a core 12 out of a material having a large modulus of elasticity E 1 and of thickness h 1 that is constant or that increases as shown going from the edge 13 towards the center 14 , and a covering 15 that extends on either side of the core 12 and that is made of a material having a lower modulus of elasticity E 2 and of thickness 2×h2 that decreases from the edge 13 towards the center 14 . The assembly is made in such a manner that the quantity
[0000] E 1 ×h 1 +E 2×2 ×h 2
[0000] increases from the edge 13 towards the center 14 sufficiently to impart a propagation speed to the traveling wave that deforms the diaphragm 12 such that the propagation speed increases more quickly than the decrease in the working section for fluid flow. With reference to the embodiment referenced C, the diaphragm 21 is constituted by a material that is homogeneous. It is cut into the shape of a disk of thickness h that is generally decreasing from the edge towards the center, and in which annular grooves are formed at intervals that are regular in this example so as to leave a core that is of thickness that is constant in this example. The density of the material is written p and the density per unit area of the diaphragm is equal to the product pxh, with the grooves being arranged in such a manner that the mean of the quantity pxh over a distance d including a trough and a ridge decreases on approaching the center, such that this technical configuration also gives rise to progressive variation in the propagation speed of the wave.
[0026] With reference to another embodiment referenced D, the diaphragm 31 comprises a core 32 made of a material having a large modulus of elasticity E 1 and a constant thickness h 1 , together with a covering 35 made of a material having a small modulus of elasticity E 2 and presenting annular grooves as in the above-described embodiment.
[0027] In yet another embodiment, as shown in FIG. 3 , the diaphragm 41 includes a neck 45 at its center, the neck extending along the axis Z into the delivery duct 46 at the outlet from the propulsion chamber. The neck 45 forms a stiffener that contributes to increasing the stiffness of the diaphragm towards its center 44 , such that the propagation speed of the traveling wave increases.
[0028] In addition, the neck 45 offsets the point where the fluid flows on either side of the diaphragm 41 join together to outside the propulsion chamber, and it makes use of the dynamic pressure of the fluid at the outlet from the neck so as to conserve a pressure differential between the faces of the diaphragm in its central portion inside the propulsion chamber. The central portion of the diaphragm thus works under better conditions, and the efficiency of the pump is thus improved.
[0029] In FIG. 5 , the diaphragm 71 comprises a core 72 made of a material having a large modulus of elasticity and presenting in the vicinity of its edge 73 a peripheral zone 75 that is made more flexible by having a profile in the form of wavelets 76 that make the diaphragm 71 more flexible in the vicinity of its edge 73 .
[0030] In FIG. 6 , the core 72 is embedded in a layer 76 of flexible material that forms a covering. In the embodiment of FIG. 7 , the diaphragm 71 comprises a core 72 made of a material having a large modulus of elasticity that is provided in the vicinity of its edge 73 with a flexible peripheral zone 75 presenting a profile of crenellations 77 imparting flexibility to the vicinity of the edge 73 .
[0031] As can be understood from the above, the above-described embodiments relate to diaphragms forming bodies of revolution and having mechanical characteristics that are constant along any circle centered on the central axis Z, even though those characteristics vary radially going from the edge towards the center.
[0032] Nevertheless, it is possible while remaining within the ambit of the invention, to provide diaphragms in which the mechanical characteristics vary radially, but are not necessarily constant around a circle. Thus, as in the embodiment shown in FIG. 4 , the diaphragm 51 may be made in composite manner with a star-shaped stiffener 52 made of a material having a large modulus of elasticity, comprising a central ring from which branches project. The stiffener 52 is incorporated in a web 55 made of a material having a small modulus of elasticity. In the same manner as described above, this type of diaphragm enables a traveling wave starting from the edge 53 and going towards the center 54 to propagate at a speed that increases.
[0033] In the embodiment of FIG. 8 , the diaphragm 61 comprises a core 62 carrying ribs 65 that extend radially from the center 64 of the diaphragm 61 towards the edge 63 as far as a middle portion of the diaphragm 61 between the center 64 and the edge 63 . The ribs 65 are of decreasing height such that the ribs 65 present a maximum height close to the center 64 and zero height in the middle portion.
[0034] The core 62 is made of a material that is relatively flexible and that is stiffened progressively by the ribs 65 going towards the center 64 .
[0035] The core 62 may optionally be covered by a covering so that the diaphragm presents faces that are plane.
[0036] The invention is not limited to the description above, but on the contrary covers any variant coming within the ambit defined by the claims.
[0037] In particular, although the invention is described with reference to diaphragms that are disk-shaped, it is clear that the invention applies equally well to diaphragms that are strip-shaped or that are tubular. It should be observed that in pumps that use diaphragms of this type, the working section for fluid flow through the propulsion chamber decreases only because the two end plates come closer together and possibly also because the diaphragm becomes thicker, but at a rate that is slower than in pumps having disk-shaped diaphragms of the kind described above. The variation in speed between the inlet and the outlet of the propulsion chamber is thus less marked. As a result, the variation in the mechanical characteristics of the diaphragm for causing the propagation speed of the wave in the diaphragm at all cross-sections relative to fluid flow inside the propulsion chamber to be equal to or greater than the travel speed of the fluid in said section takes place more slowly and it is therefore easier to implement.
[0038] In a variant, the modulus of elasticity E of the diaphragm may vary more slowly than the thickness of the diaphragm decreases, but the performance of the pump will nevertheless be diminished compared with the embodiment described.
[0039] In a variant, diaphragm may be made of a single material that is treated locally so as to obtain variation in its modulus of elasticity (the treatment may be hot deformation, particle bombardment, local doping, . . . ).
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An undulating diaphragm pump having a propulsion chamber for receiving said diaphragm, wherein the diaphragm has mechanical characteristics that vary from an inlet of the propulsion chamber towards an outlet of the propulsion chamber in such a manner that, when the diaphragm is actuated to deform with a traveling wave that propagates from the inlet towards the outlet of the propulsion chamber in order to propel the fluid, the propagation speed of the wave in the diaphragm in any cross-section relative to the movement of the fluid inside the propulsion chamber is equal to or greater than the mean travel speed of the fluid in said section.
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This is a continuation of application Ser. No. 376,443, filed May 10, 1982, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a device for retaining at least two specimen collecting tubes in a preselected spaced relationship and, more particularly, to a clamp for interconnecting tubes containing separated phases of a body fluid, such as blood.
It is universally required that samples of blood drawn for cross-matching in connection with blood transfusions be centrifuged and that the serum be separated therefrom immediately after clotting. This procedure curtails auto absorption. The phases of blood obtained in this way must be maintained in a separated condition and identified with the patient for future reference.
Systems have been devised for correlating the various samples and units of blood taken from a particular patient and identifying them with the patient. One such system includes a pair of specimen container tubes having color coded stoppers and suitable patient identifying indicia which is also found on a wrist band worn by the patient. However, the specimen containing tubes of such systems are likely to become separated or lost, causing valuable time to be lost in locating them before a blood transfusion can be administered. Although it is possible to maintain the tubes for a given patient in close proximity in a tube rack, it is both inconvenient and time consuming to cross check the indicia on the tubes each time they are removed from the rack. The possibility also exists that a worker in an emergency will pull a clot tube from one patient and a serum tube from another.
Attempts have also been made to physically connect the clot and serum tubes of each patient to avoid confusion and assure proper match. In some cases, the clot and serum tubes are held together by tape and rubber bands. However, tubes connected in this way are difficult to maintain upright because they do not fit within conventional tube racks.
Another proposal for correlating specimen tubes is disclosed in pending U.S. patent application Ser. No. 199,251, filed Oct. 21, 1980, now abandoned, by Mark O. Walker. The Walker application relates to a spacer positioned between a pair of collecting tubes to hold the tubes together. The spacer is adhesively bonded at one side to a clot tube and is either formed integrally with or adhesively bonded to a serum tube at its other side. However, the Walker structure can be somewhat expensive to produce and assemble due to the use of adhesives. It is also possible that the adhesive will fail, causing the tubes to become separated. When the spacer is formed integrally with the serum tube, the proposal requires a nonstandard tube which increases cost.
Therefore, in many applications it is desirable to provide a device and system for holding related specimens of body fluids together indefinitely and permitting the specimens to be easily stored in that condition.
SUMMARY OF THE INVENTION
The present invention includes a device for retaining at least two specimen collecting tubes in a preselected spaced apart relationship, comprising an elongated structure having first and second arm portions joined by a flexible hinge portion, each of the arm portions defining a first surface engageable with a first specimen collecting tube and a second surface engageable with a second specimen collecting tube, the surfaces of the two arm portions being positioned symmetrically relative to the hinge portion, and means for joining the arm portions to each other at locations remote from the hinge portion to confine the tube between the arm portions. In a preferred embodiment, the arm portions are formed integrally with the hinge portion and the elongate structure is formed of a suitable injection molded polymeric material. The joining means may then comprise at least one enlarged projection on one of the arm portions which is receivable within a restricted opening of the other arm portion, the projection having an undercut portion engageable with the restricted opening when the projection is received therein.
The device of the present invention is suitable for frictionally holding a pair of specimen collecting tubes in a spaced relationship. The tubes can be handled together and readily identified as belonging to the same patient. The tubes themselves are conventional evacuated blood sampling tubes or other suitable tubes of appropriate diameter. In addition, the connected tubes can be stored in an upright condition within adjacent openings of a conventional tube rack.
The simplicity of the clamp device of the present invention permits it to be manufactured inexpensively and to produce highly consistent results. The flexible "living hinge" formed between the first and second arm portions permits the clamp to be mass produced by injection molding in an open condition from an organic polymeric material. The hinge portion is much thinner than the arm portions, causing it to experience substantial deformation between the open condition of formation and the closed condition of use.
The clamp device of the present invention is thus suitable for use as a "one shot" device for assembly about a pair of conventional collector tubes just prior to use. After use, the tubes and the clamp can be discarded as a unit. The device can be produced inexpensively and is assembled by simply snapping it in place around the tubes. Expenses for material and labor are thus minimized while providing an extremely workable solution to the problem of correlating blood specimens.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention may be more fully understood from the following detailed description, taken together with the accompanying drawings, wherein similar reference characters refer to similar elements throughout and in which:
FIG. 1 is a perspective view of the tube clamp device of the present invention assembled about a pair of specimen collecting tubes;
FIG. 2 is a horizontal sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a front elevational view of the tube clamp device of FIG. 1 in the open condition;
FIG. 4 is a horizontal sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is an enlarged vertical sectional view taken along the line 5--5 of FIG. 3; and
FIG. 6 is an elevational view of the apparatus of FIG. 1 in position within a conventional tube rack.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, there is illustrated in FIGS. 1 and 2 an apparatus constructed according to the present invention, generally designated 10. The apparatus 10 comprises a clamp device 12 positioned around a first tube 14 and a second tube 16 to frictionally retain the tubes in a preselected spaced apart condition. The tubes 14 and 16 are preferably conventional specimen collecting tubes for reception of different phases of blood or other body fluid from a particular patient. Upon drawing one or more specimens, the clamp 12 is positioned about the tubes to prevent them from being lost or confused with tubes containing specimens from other patients. When the specimens are no longer needed, the entire apparatus can be discarded as a unit.
Referring to FIGS. 2, 3 and 4, the clamp 12 comprises a first arm 18 and a second arm 20 connected by a living hinge 22. The first and second arms are in large part mirror images of each other. The first arm 18 includes a first arcuate portion 24 and a second arcuate portion 26, and the second arm 20 comprises a first arcuate portion 24' and a second arcuate portion 26'. The first and second arcuate portions of the respective arms are positioned symmetrically relative to the hinge 22, forming a first composite surface 28 for engaging the tube 14 and a second composite surface 30 for engaging the tube 16.
The arcuate portions of the arms 18 and 20 are connected together by substantially flat surface portions 32 and 32', respectively, and by a plurality of horizontal strengthening flanges 34. The flat portions 32 and 32' extend between adjacent ends of the corresponding arcuate portions, while the flanges 34 are perpendicular to the flat portions. The flanges 34 and the substantially flat portions 32 combine with the arcuate portions to provide substantially rigid portions along the greater part of each of the arms. Flexing of the clamp 12 is substantially limited to the living hinge 22 and the outer ends of the first arcuate portions 24 and 24'.
The "living hinge" 22 is formed of a relatively thin strap of organic polymeric material extending between the second arcuate portion 26 and the second arcuate portion 26'. In the preferred embodiment in which the clamp is a single injection molded plastic part, the hinge is made of the same material as the remainder of the clamp. The greater flexibility of the hinge results from its configuration and relative thinness. When the clamp 12 is formed of polypropylene or other suitable injection moldable material, it can be repeatedly flexed open and closed relative to the hinge 22 without damaging the hinge in any way. The hinge is thus "living" in the sense that it is not detrimentally affected by such flexing movement.
In the condition of FIG. 2, the first and second arms are held about the tubes 14 and 16 by a central connecting structure 36 and an outer connecting structure 38. The central connecting structure 36 comprises an enlarged projection 40 extending from the flat portion 32 for engagement with a tapered opening 42 of the flat portion 32'. The projection 40 is preferably pointed for ease of reception within the tapered opening 42, and is provided with an undercut portion or stem 44 engageable with the opening after the projection has been passed therethrough. The opening 42 is then permitted to recover inwardly toward the undercut portion 44, preventing the projection from being easily withdrawn. Thus, the projection 40 snaps readily through the opening 42 to connect the flat portions 32 and 32' when the clamp device is positioned about the collecting tubes, and is held in that position in the absence of a much greater force in the opposite direction. It will be noted that in the engaged condition of the connecting structure 36, the flat portions 32 and 32' are held substantially parallel to each other, as shown in FIG. 2. This forces the second composite surface 30 and the living hinge 22 into a circular configuration about the tube 16, causing the clamp 12 to uniformly grip the two tubes.
The outer connecting structure 38 is provided with a pair of ears 46 and 48 which extend outwardly from the free ends of the first arcuate portions 24 and 24'. The connecting structure 38 includes a projection 50 of the ear 46 which is received within an opening 52 of the ear 48. The projection 50 is provided with a tapered end 54 for ease of insertion into the opening, and with an undercut portion 56 for engaging the opening in the manner of the undercut portion 44 discussed above. The projection 50 and the opening 52 are preferably in the form of a tongue and a slot, respectively, for engagement as shown in FIG. 2. The connecting structure 38 acts in much the same way as the connecting structure 36 described above, in that the tapered end 54 of the projection 50 is able to snap rather readily through the opening 52 to connect or join the two ears, but will not disconnect unless a much greater force is applied in the opposite direction.
The connecting structures 36 and 38 permit the clamp 12 to be quickly and easily assembled about a pair of specimen collecting tubes without the need for tools or special training. The result is a force fit between the arcuate surfaces and the corresponding tubes. The friction between the arcuate surfaces and the tubes is controlled by a plurality of tube engaging ribs 58 on the arcuate surfaces, as seen most clearly in FIG. 5. The tubes are thus held indefinitely within the clamp against the forces encountered in handling of the tubes, but either or both of the tubes can be pulled axially from the clamp for individual centrifuging or other processing. Upon completion of processing, the tube can be reinserted into the clamp for continued correlation of the samples.
As seen in FIG. 6, the apparatus 10 can be inserted within a conventional tube rack 60 in its assembled condition. Each of the individual tubes engages one of the tube openings 62 of the rack. The first tube 14 will generally be somewhat longer than the second tube 16, and will also engage a bottom 64 of the rack to hold the apparatus in position. Although the rack depicted in FIG. 6 is a cross-wire rack, the principal illustrated therein is applicable to a wide variety of conventional tube racks.
In practice, a nurse or medical technician will typically close the clamp 12 by engaging the connecting structures 36 and 38 before inserting the tubes therein. In the preassembled condition, the composite surface 30 forms an oblong opening with the living hinge 22. This occurs because the living hinge is the most flexible part of the clamp and therefore the most easily distorted when the clamp is closed. The surface 30 and the hinge 22 are subsequently forced into a circular configuration by insertion of the second tube 16. Since the arms 18 and 20 are joined by the projection 40 and are substantially rigid adjacent thereto, they act as a "scissors" type of arrangement to reduce the circumference of the first composite surface 28 when the second tube 16 is inserted. The first composite surface is then prepared to receive the first tube 14, after which the apparatus 10 is fully assembled to apply a uniform frictional force to the tubes. Suitable identifying indicia (not shown) may be applied to the apparatus 10 at this time, if desired. As discussed above, the apparatus 10 may be discarded after a single use.
In the field of cross-matching blood, the first tube 14 is typically an evacuated blood sampling tube of the type available commercially from a number of sources and the tube 16 is a smaller serum tube for retaining blood serum from a drawn sample which has been centrifuged. The sizes of the tubes depend primarily upon the circumstances of their use and the clamp 12 must be dimensioned to produce a force fit of the tubes therein.
Although the present invention has been described primarily in relation to use in the cross-matching of blood, it is anticipated that the apparatus will find application in a variety of other fields wherein sets of fluids must be correlated for future testing or inspection.
From the above, it can be seen that there has been provided an improved disposable apparatus for releasably holding a plurality of specimen collecting tubes together.
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A device for retaining at least two specimen collecting tubes in a preselected spaced relationship includes an elongate structure having first and second arm portions joined by a flexible hinge portion, each of the arm portions defining a first surface engageable with a first tube and a second surface engageable with a second tube. The device includes provision for joining the arm portions to each other at locations remote from the hinge portion to confine the tubes between the arm portions.
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BACKGROUND OF THE INVENTION
This invention is directed to a snap closure of a particular design which permits the snap closure to properly retain and release opposite parts when the opposite parts are made of a resilient thermoplastic polymer composition material.
Injection molding of housings employing thermoplastic polymer composition material is an economical way of producing such housings. In the conventional construction, the top and bottom are separately molded of relatively rigid material which may be thermoplastic or thermosetting plastic. Hinges are provided so that the top and bottom may swing open and closed with respect to each other. A closure device is provided opposite the hinge, and as long as the top and bottom are both of relatively rigid construction, the latching forces can be resolved back to the hinge. However, for more flexible and resilient molding material, such catches are unsatisfactory because the flexibility of the top and bottom of the housing do not permit the continued maintenance of adequate snap closure forces. Thus, there is need for a construction whereby a snap closure maintains its latching and unlatching characteristics even when molded of resilient material.
SUMMARY OF THE INVENTION
In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a molded housing having a top and a bottom and each having an edge, with a catch on one edge and a latch on the other. A flange is positioned opposite the latch to engage the other edge therebetween for a properly acting snap closure.
It is, thus, an object of this invention to provide a snap closure which is capable of being molded in resilient thermoplastic polymer composition material and provide good closure retention and closure release capabilities.
It is a further object to provide a snap closure in a housing having a top and a bottom with a living hinge therebetween and a snap closure opposite the living hinge so that the entire structure can be molded in one piece, with the snap closure providing reliable retention and release over a long life.
It is a further object to provide a snap closure for a housing having a top and bottom with facing edges, with one of the edges provided with a channel into which at least a portion of the opposite edge is received for relative restraint of the edges for provision of a reliable snap closure.
The features of the present invention which are believed to be novel are set forth with particularlity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may be best understood by reference to the following description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the front of a housing having the snap closure of this invention.
FIG. 2 is an isometric view of the rear of the same housing.
FIG. 3 is an enlarged isometric view, with parts broken away, showing the snap closure of this invention. in the upright position.
FIG. 4 is a view similar to FIG. 3, with the snap closure shown in inverted position.
FIG. 5 is an enlarged section taken generally along the line 5--5 of FIG. 1, with parts broken away.
FIG. 6 is a section taken generally along the line 6--6 of FIG. 5, with parts broken away.
FIG. 7 is an enlarged section through the snap closure, taken generally along the line 7--7 of FIG. 1, with parts broken away.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Snap closure 10 of this invention is particularly useful when employed with a housing made of soft or resilient material. Thus, snap closure 10 is illustrated in conjunction with housing 12. Housing 12 can be of any convenient shape or structure to enclose the contents in question. In the present case, housing 12 has a top 14 and bottom 16 which have front, side and back walls of the same depth on the top and bottom so that they are substantially equally recessed. Snap closure 10 is particularly designed to be useful on a housing which is injection-molded of relatively soft and flexible thermoplastic synthetic polymer composition material, of which polypropylene is an example. In view of the flexibility of the material from which housing 12 is made, it is convenient to mold the housing 12 in one piece with a living hinge 18, see FIGS. 2 and 5. When a living hinge is employed, the use of polypropylene as a material from which the housing is formed is particularly advantageous because properly formulated and molded polypropylene becomes more flexible with use and does not break from brittle failure at the hinge.
The top 14 and bottom 16 of housing 12 face each other and are releaseably latched together by snap closure 10. As is seen in FIGS. 3 and 5, top 14 terminates in edge 20 interiorly of which there is a recess 22. As is seen in FIG. 5, edge 20 and recess 22 extend all the way around the lower periphery of top 14. That portion of the bottom 16 which faces those portions of the top are flange 24 and lip 26. These features extend all the way around the periphery of bottom 16. It is important to note that flange 24 extends upwardly into top 14 interiorly of edge 20 and substantially engages against recess 22. Similarly, edge 20 substantially engages against lip 26 when the top is closed with respect to the bottom. These peripheral features of the top and bottom are sufficiently loose so that the top may be raised away from the bottom, hinging on living hinge 18 to open, and subsequently close the housing. The outer surface 28 of edge 24 engages around the inner surface 30 of edge 20. When in the closed position, this interengagement provides lateral positioning of top 14 with respect to bottom 16.
Snap closure 10 is formed with a catch 32 formed on the outside of edge 20 and with a latch 34 formed on the bottom 16 adjacent lip 26. As is seen in FIGS. 3 and 5, wall 36 is formed on the outside of bottom 16 and extends upwardly beyond lip 26, substantially even with the top edge of flange 24. Upstanding wall 36 defines channel 38 between outer surface 28, lip 26 and wall 36. When in the closed position, edge 20 extends down into this channel. On the upper interior of wall 36, the latch 34 is formed as an inwardly directed rib. Similarly, catch 32 is formed on the lower, outer surface of edge 20 as a protrusion. Both protrusions extend generally parallel to the length of edge 20 and substantially parallel to the hinge line of living hinge 18.
The resiliency of wall 36 permits latch 34 to swing outwardly away from catch 22 to permit the entry of the catch into the channel and to permit the release of the catch from the channel. Catch 32 is maintained in resilient engagement position with latch 34 by engagement of the inner surface 30 of edge 20 against the outer surface 28 of flange 24. Thus, flexure of the top and bottom of the housing toward or away from the hinge does not change the engagement of the latch with respect to the catch. The backup force provided by inner surface 30 engaging on outer surface 28 at a position directly opposite where catch 32 engages on latch 34 provides the positive snap closure action.
Closure of the housing 12 easily accomplished by pressing the top down onto the bottom. Edge 20 enters channel 28 so that catch 32 and latch 34 interengage. Wings 40 and 42 are respectively secured to the top and bottoms 14 and 16 adjacent catch 32 and latch 34. They are positioned so that when they are engaged by the forefinger and thumb of the right hand, respectively, and the thumb and finger are twisted in the clockwise direction, an opening couple is produced. It is convenient to form the wing 42 in line with wall 36 so that they are in line with each other and show a continuous surface. In view of the fact that the space under latch 34 is wider than the channel 38, some reinforcement such as fillet 44 can be provided for strengthening the portion adjacent latch 34. As is seen in FIGS. 3 and 6, latch 34 can be formed as a continuation of wing 40, but of smaller size. As is seen in FIGS. 1 and 7, the wings 40 and 42 are of substantially equal length and are directly adjacent each; and, as seen in FIG. 1, these wings are substantially centrally located at the periphery of the top and bottom opposite the hinge. As is seen in FIG. 7, the channel 38 passes behind wing 42, and the latch 34 is formed within the length of the wing 42. Thus, the wings 40 and 42 are directly associated with catch 32 and latch 34 so that when they are grasped and force in the opening direction is applied, the opening force is applied directly at the catch and latch so that it is directly effective in opening of the snap closure. The catch and latch are designed for a positive feeling snap in both the opening and closing operation. Thus, a snap closure which can be molded into a housing of soft and resilient thermoplastic synthetic polymer composition material is achieved.
This invention has been described in its presently contemplated best mode, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.
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Housing has a top and bottom and has a living hinge joining them so that the top and bottom are of monolithic construction of a thermoplastic polymer composition flexible material. The top and bottom are configured so that opposite the hinge an edge on the top with a catch thereon enters between a flange and latch on the bottom so that the latch resiliently engages over the catch to detachably hold the top and bottom in the closed position.
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SUMMARY OF THE INVENTION
The present invention relates to a wine cork which is particularly adapted for use with still wines. The cork is fabricated from two pieces of plastic of different colors and the colors are normally selected so that the cork simulates the conventional covered cork made of natural material. In the past, plastic corks have normally been associated with relatively inexpensive wines but the cork of the present invention is so attractive that it can be used with the most expensive wines. The cork of the present invention has a positive sealing system so that it is not ordinarily necessary to keep the bottle on its side to maintain a wet cork as must be done with corks of natural material.
Although the cork of the present invention is made of two pieces, they are snapped together in such a way that the two pieces will not rotate relative to each other, facilitating pulling the cork out of the bottle. This is done without the use of adhesives. Further, the two pieces of the cork are engaged throughout a substantial portion of their length, including almost the entire height of the cap portion, producing a very stable structure. The top will not rock with respect to the bottom. Further stability is achieved by providing a plurality of buttresses within the hollow body of the top of the plug portion.
The cork of the present invention so nearly simulates a standard bottle cork that it can be used with standard bottling equipment without modifying the equipment.
Various other features and advantages of the invention will be brought out in the balance of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the two piece cork of the present invention.
FIG. 2 is an enlarged section on the line 2--2 of FIG. 1.
FIG. 3 is a section on the line 3--3 of FIG. 2.
FIG. 4 is an enlarged partial section on the line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings by reference characters, the two piece wine cork of the present invention consists of a bottom portion generally designated 6 and an upper portion generally designated 8. The bottom portion includes a cylindrical plug portion 10 having a closed bottom 12 and a hollow interior 14. Obviously, the plug portion is selected of such size as to fit snuggly within the neck of a standard wine bottle. The plug has a plurality of circumferential ridges 16 thereon, to insure a good seal in the neck of the bottle. Since the bottom of the plug portion is sealed by the member 12, the wine never comes into contact with the hollow interior of the plug.
The closed bottom portion 12 is arched as shown which facilitates uniform compression of the plug without localized deforming of the sides or end (such as a crease or wrinkle) thus avoiding leakage. The compressed configuration of the plug is shown in dash lines in FIG. 2.
The bottom of the plug is tapered as at 13 to facilitate inserting the plug in bottles 11 of smaller diameter.
Located above the plug portion and formed integrally therewith, is a flat circular rim portion 18 and somewhat larger diameter than the plug.
Formed within the cylindrical shoulder are a series of triangular buttress members 22. These extend from the top 24 of the cylindrical shoulder to the inner surface 26 of rim 18.
The top portion 8 has a gently rounded outer surface 28 which gives a pleasing affect. The interior surface 28 of the top is cylindrical and is complementary both in diameter and in height to the cylindrical shoulder 20. Thus, the top when it is snapped into position as is later described, is held securely against wobbling both by contact with the side wall of the cylinder 20 and the top edge of the cylinder 24 as is best seen in FIG. 2. Near the bottom of the inner surface 28, a groove 30 is formed and the terminal edge of the cap is wedge shaped as at 32 so that the top snaps over the bottom portion with the rim 18 engaged in the groove 30. The rim 18 and the groove 30 have complementary ridges and depressions as at 34 and 36 which prevent the parts from rotating relative to each other. This is important since wine bottles are ordinarily opened by grasping the top and twisting it.
Preferably the top 8 and the plug portion 6 are made in contrasting colors to have an attractive appearance and to simulate conventional corks having a natural cork plug and a decorative top of wood or plastic.
The top of the present invention is very stable which is brought about by the large area of contact between the outer surface 20 of the cylindrical portion and the inner surface 28 of the top as well as a direct contact with the top of the cylinder within the interior surface of the top. Thus, the cork of the present invention merely snaps together so that it is not necessary to use any adhesive yet it is extremely strong so that it can be twisted or rocked back and forth without displacing the parts from each other. The interior buttress members 22 give great rigidity to the structure, allowing reduction in weight as well as a reduction in plastic.
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A two piece plastic closure is provided which is particularly adapted for still wines and which has substantially the same appearance as conventional corks made from natural materials.
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BACKGROUND OF INVENTION
[0001] This invention relates to electromagnetically actuated mechanical brakes, and more particularly, to such brakes arranged in interleaved stacks.
[0002] In the prior art, electromagnetically actuated mechanical brakes having multiple discs are known. These may be operated as follows: normally the discs are forced together by a spring. When current is applied, an armature is attracted toward a magnetic body, thereby compressing the spring and releasing the discs; thus allowing them to be rotated. When current is discontinued to the coil, the spring pushes the armature into engagement with the discs, forcing them together to stop the movement of the load. Thus the device holds the load with the power off.
[0003] The discs are complete circles and are generally acted upon by a centrally disposed spring and armature. This configuration is both bulky and heavy. For example, a 360 degree brake to produce 90 foot pounds of torque would have a diameter of approximately 7 inches and weigh approximately 30 pounds.
[0004] It is desirable to make such breaks lighter and more compact; so that they can fit into small mechanical devices.
SUMMARY OF INVENTION
[0005] I have invented a new and improved disc brake which is particularly designed for arcuate travel of less than 360 degrees. In such devices, I use segments of discs which segments are not complete circles. I interleave these disc segments. Some segments are rotatable about an axis and have friction brake material carried on them at a position remote from the axis of rotation.
[0006] I have also invented such a brake wherein some segments have holes there through to make them lighter. Also, I provide friction material on some segments which material is circular in plan view.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an exploded perspective view of parts of one embodiment of my invention;
[0008] FIG. 2 is a side elevation of the parts shown in FIG. 1 , reoriented to the vertical and assembled with additional parts;
[0009] FIG. 3 is a section of an electromagnetically actuated armature and spring assembly of my device (as shown in FIG. 2 ), shown mounted to a frame;
[0010] FIG. 4 is a plan view of an inner disc segment shown in the prior figures;
[0011] FIG. 5 is a plan view of an outer disc segment assembly shown in the prior figures; and
[0012] FIG. 6 is an enlarged cross section of a portion of the outer disc assembly shown in FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring to the figures, FIG. 1 shows a plurality of pie shaped segments of discs. A plurality of these are arranged in an interleaved disc pack designated generally 10 , FIG. 2 . The inner disc segments 12 are spaced from the outer disc segments 14 by spacers 16 . All are arranged about a shaft 20 . The inner disc segments 12 rotate with the shaft. The outer disc segments are stationary. In operation, the shaft is mounted in a working device (not shown in greater detail) for movement with a portion thereof.
[0014] A electromagnetically actuated armature and spring assembly is designated generally 18 . The armature 26 engages the disk pack 10 . This is shown in elevation in FIG. 2 and in section in FIG. 3 . It comprises an outer body 22 , a coil 24 , an armature 26 and a spring 28 . The outer body 22 is designed to be fixedly mounted to the frame 30 of the working device (referred to above).
[0015] An inner disc segment 12 is shown in FIG. 4 and has a plurality of holes 32 there through to make it lighter in weight without sacrificing its strength. The material may be hard anodized aluminum to reduce wear.
[0016] The outer disc segment 14 is fixedly mounted on the working device as at 34 . It has a plurality of holes 36 there through to make it lighter in weight without sacrificing its strength. The material may be clear anodized aluminum. The segment 14 carries a disc friction puck 40 on each side (see FIG. 6 ) positioned near the end remote from the shaft 20 . These pucks are, most preferably, retained by adhesive on the surface of the disc segments; but may also be retained by any suitable means, such as, molding in place or riveting.
[0017] In operation, the spring 28 exerts a force against the armature 26 which engages and exerts a force upon the disc pack 10 to force the interleaved disc segments toward one another and engage the other friction pucks 40 . This is the normal at-rest condition in which the brake is locked. When an electricity is applied to the electromagnet, the armature 26 retracts against the spring 28 and compresses it, thereby allowing the segments to move. This allows repositioning of the working device.
[0018] Breaking action is a function of the number of pucks, the coefficient of friction of the puck material, the spring force and the moment arm between the axis of rotation (at the shaft 20 ) and the radial position of the puck on the disc segment.
[0019] In one embodiment of my invention, the inner disc segments 12 can be rotated 15 degrees in each direction for a total travel of 30 degrees. The brake is stopped by mechanical stops in the working device which limit the travel of the brake. The surface area identified generally as “A” in FIG. 1 , must be sufficient to engage the pucks a various positions throughout the expected range of travel of the discs. While 30 degrees is preferable for some devices, it will be understood that this invention may be applied to other ranges (more or less than 30 degrees) for working devices such as x-ray machines, CT scanners, MRI's, ultrasound apparatuses and the like. But for 30 degrees, in the example given above, my arc brake would be 5 inches (as opposed to 7 inches) and the weight would be 1.1 pounds (rather than 30 pounds) for 90 foot pounds of torque.
[0020] Although this design is for a normally off device, it will be understood that it can also be operated as a power on brake or a bi-stable pulse operated brake.
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A disc brake which is particularly designed for arcuate travel of less than 360 degrees has pie shaped segments, i.e. segments which are not complete circles which are interleaved. Some segments are rotatable about an axis and others are stationary and have friction brake material carried on them at a position remote from the axis of rotation.
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RELATED APPLICATIONS
The present invention was first described in U.S. Provisional Patent Application No. 60/734,437, filed on Nov. 9, 2005.
FIELD OF THE INVENTION
The present invention relates generally to an apparatus and a method for accurately and safely cutting residential siding and, more particularly, to a specialized tool with a resilient saw guide system that results in straight edge cuts and angled cuts to conform with roof pitches
BACKGROUND OF THE INVENTION
As any professional contractor will attest, nothing beats having the proper tool for a job. The proper tool can save time, save money, produce a higher quality job, reduce damage to equipment, and provide for the increased safety of the worker. Each field of construction or contracting work has its own type of specialty tools, each performing a specialized task. One field where such a need exists is that of vinyl siding installation. While, at first, installation of vinyl siding may seem straightforward and uncomplicated, there are many cuts that must be made at precise angles so that the finished installation looks aesthetically pleasing. Many contractors use simple straight edges and circular saws, which provide for quick, burr-free cuts, but often result in cracked siding or cuts with chunks missing, due to the fact that the siding is not fully supported during the cutting process. The cut must then be remade, which not only results in wasted time, but wasted material as well. The development of this apparatus and system fulfills this need.
The invention consists of two metal plates connected by a hinge or series of hinges along one edge. A piece of vinyl siding is placed between the metal plates, and the plates are then closed together forming a “sandwich” of vinyl siding. One end of the plate is cut at a 90° angle, forming a straight cut. The other end would be cut to match the roof pitch, which is one of the most common cuts made to vinyl siding along the roof line. Then, a circular saw with the appropriate blade is run along the desired edge in a guide system on the upper plate of the invention. This method assures that the cut will be extremely true and accurate, while eliminating the possibility of cracked or gouged siding, since it is securely supported on all edges. The invention would be available in multiple models to match the most common roofline pitches such as 4/12 (drop of four inches per running foot), 6/12, or 8/12. This apparatus and system provides a safe and efficient means of cutting with a circular saw on the job site to match various roof pitches.
Several attempts have been made in the past to provide a device that constantly and accurately measures and cuts structural siding members at various angles. U.S. Pat. No. 5,249,495, issued in the name of Renk, discloses a shingle cutter apparatus including a rigid base plate, a cutter anvil, and a pivotal cutter blade mounted in cooperation with the anvil. Unfortunately, the Renk device does not provide any means to attach and guide a circular saw as in the present invention.
U.S. Pat. No. 6,334,259, issued in the name of Harvey, teaches a scoring tool for siding material and method of use, comprising an extensible measuring rail with a scoring knife attached thereto, wherein the rail and knife assembly interlocks with the siding material. The Harvey device differs from the present invention in that it does not retain the siding material within two hinged plates with marking and/or guide means for a circular saw to cut said siding material.
U.S. Pat. No. 4,903,409, issued in the name of Kaplan et al., describes a drywall scribing and scoring tool for a typical wallboard, wherein a knife-holding and scribe units are adjustably attached on an arm of a “T”-square member. The Kaplan et al. device also does not provide means to retain a siding material within hinged plates comprising fixed cutting angles and having means to guide a circular saw for cutting the siding material.
U.S. Pat. No. 6,240,764, issued in the name of Geurts, discloses a “J”-channel siding cutting tool used to cut tabs or notches or a miter finishing cut in “J”-channel vinyl or aluminum siding, comprising a pair of pivotable interconnected handles with two cutters and a biasing member for urging the handles apart and separating the cutters at the at-rest position, and a travel limiter. The Geurts device is designed to be held in the hands of a user to cut specifically styled siding by hand and does not have the features or benefits of the present invention.
U.S. Pat. No. 5,203,090, issued the in name of Bouska et al., teaches a siding layout and tool and method for making a longitudinal mark on, or cut through, a piece of siding. The Bouska et al. patent comprises an upper and lower plate portion with a step therebetween, adapted to fit onto a piece of siding. The two plates have a predetermined series of holes along the length of the tool, wherein a marking tool and/or a knife can be inserted through to scribe or cut the siding. Unfortunately, the Bouska et al. device does not have means to guide a circular saw along an angled edge to cut the siding member as in the present invention.
Additionally, various patents have been issued concerned with the ornamental design of various siding cutter devices, notably D 386,663 issued in the name of Kehres et al. and D 363,013 issued in the name of Hunter.
None of the prior art particularly describes a device that guides a cutting instrument along resilient guide members wherein the siding member is “sandwiched” in between hinged plates. Accordingly, there exists a need for a means by which vinyl siding can be cut with a circular saw without the disadvantages listed above.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is need of a device to assist in cutting siding.
It has further been observed that there is a need for a device that has a plurality of different sizes, based on common roof angles.
The object of the present invention is to provide a device, comprising two hingedly connected plates, preferably fabricated out of metallic or other resilient material, each comprising a first edge maintaining a 90° angle for straight cuts; a hinged edge; an open edge; and a second edge embodying varying angles most commonly matching that of conventional roof pitch angles to permit directing a cutter blade, said plates encompass a siding member for preparing a cut. Each plate has a lip formed about its hinged edge and open edge that abuts when both plates are hinged together, thereby forming an interior through which a siding member is placed. The length and width of the plates may vary in accordance to size of siding to be trimmed and the roof pitch, as well as other user preferences.
Another object of the present invention is to provide a first guide track, located on the front plate, running parallel to the open edge and a second guide track, located on the front plate, running parallel to the hinged edge.
Yet another object of the present invention is to provide a straight cut guide slidably engaged within the first guide track and a roof pitch cut guide slidably engaged within the second guide track. Each guide adjustably progresses longitudinally and/or slantingly at interval adjustments and is designed to assist in guiding a cutting instrument at a chosen angle.
Still yet another object of the present invention provides for a pair of resilient stops placed within opposing ends of each guide track to prevent the guides from unwanted slippage down each guide track, that is either fabricated with a non-slip frictional composition or mechanically affixed within each the guide track. The stops act as limiters, which assist in a smooth and continuous cutting operation without slippage of the guides upon operation.
Another object of the present invention provides a clasp, locking mechanism, fastener, catch, or other detachedly affixing mechanism mechanically situated at a center location of the open edges on each plate to fasten the plates together, while encompassing the siding member.
To achieve the above and other objectives, the present invention provides for a method of utilizing the aforementioned, comprising the steps of acquiring a siding member; measuring a desired angle and marking said angle on said siding member; opening the two opposing front and rear plates about the hinges; placing said siding member therewithin the interior; closing said plates together, thereby retaining said siding member therewithin such that said siding member extends longitudinally outward; slidably adjusting said straight cut guide until the blade of a cutting instrument comes into contact with said siding member; ensuring that both stops are in place to prevent slippage of said straight cut guide; cutting said siding member by guiding said cutting instrument along said straight cut guide; slidably adjusting said roof pitch cut guide to a desired pitch angle until the blade of said cutting instrument comes into contact with said siding member; ensuring that both stops are in place to prevent slippage of said roof pitch cut guide; and, cutting said siding member by guiding said cutting instrument along said roof pitch cut guide.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols and in which:
FIG. 1 is a top view of the siding adjustable angle installation device 10 , according to a preferred embodiment of the present invention; and,
FIG. 2 is a side view of the siding adjustable angle installation device 10 , according to a preferred embodiment of the present invention; and,
FIG. 3 is a perspective view of the siding adjustable angle installation device 10 , according to a preferred embodiment of the present invention; and,
FIG. 4 is a rear view of the siding adjustable angle installation device 10 , according to a preferred embodiment of the present invention; and,
FIG. 5 is a rear view of the siding adjustable angle installation device 10 , according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10
siding adjustable angle cutting guide
11
front plate
12
hinge
13
cutting angle
14
guide track
15
straight cut guide
16
roof pitch cut guide
17
cut guide track stop
20
siding
30
rear plate
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
Referring now to FIG. 1 , a siding adjustable angle cutting guide 10 (herein referred to as the “device”) hingedly retains a piece of residential siding 20 therewithin to effect a level and straight cut for an individual piece of siding 20 during construction and installation of building materials, is herein disclosed. The device 10 is preferably fabricated of a metallic, plastic, or other suitable material using conventional die stamping and cutting techniques. The device 10 is preferably lightweight to accommodate bidirectional use by a user through operation with either hand.
Referring now to FIGS. 2 and 3 , views of the device 10 are disclosed according to a preferred embodiment of the present invention. The device 10 comprises two (2) similarly fabricated plates 11 , 30 , in the general shape of a trapezoid, comprising one (1) end maintaining a 90° angle for straight cuts and the opposite end 13 maintaining a different angle, most commonly matching that of conventional roof pitch angles to permit directing the cutter blade. The shape and degree of slope of the roof pitch edge 13 are variable depending upon the desired appearance or profile of the siding 20 . It is contemplated that the length and width of plates 11 , 30 may vary in accordance to the size of siding 20 to be trimmed and the roof pitch, as well as other user preferences.
Referring now to FIGS. 4 and 5 , front and rear views of the device 10 are disclosed according to the preferred embodiment of the present invention. The device 10 comprises two (2) plates 11 , 30 hingedly connected at one (1) end thereof. In the closed orientation, the two (2) plates 11 , 30 lie in substantially parallel planes, interconnected via hinges 12 . The device 10 comprises a front plate 11 and a rear plate 30 that are attached to each other via hinges 12 on the edge perpendicular to the straight cut and roof pitch 13 edges. In this manner, the device 10 is adapted to receive the front and rear surfaces of the siding 20 , much like sandwiching said siding 20 , wherein the front plate portion 11 is placed against the front outer surface of the siding 20 , and the rear plate portion 30 is placed against the rear surface of the siding 20 . The hinge 12 provides a pivoting feature such that the front plate 11 may pivotally lift off of the rear plate 30 to permit the insertion or removal of the siding 20 . The device 10 may then shut much like a clamshell and, thus being releaseably secured, thereby retaining the siding 20 desired to be cut. The plates 11 , 30 pivotally close, having sufficient inner area dimensions to facilitate grasping of the siding 20 of varying thicknesses. The open sides of both the front 11 and rear plate 30 of the device 10 each have a lip that abuts with each other when the plates are brought together. Although it has been illustrated that the device 10 comprises two (2) hinges 12 , it will be appreciated that the device 10 may have a plurality of hinges 12 equidistantly spaced.
Formed on the outer surface of one (1) plate 11 are grooves along the long edges to act as a guide track 14 to receive the straight cut guide 15 oriented near the straight cut edge and the roof pitch cut guide 16 oriented near the roof pitch cut edge. The guide tracks 14 are positioned along the long edges to correspondingly engage and mate with the guides 15 , 16 and stops 17 . Both guides 15 , 16 slide back and forth through the formed guide tracks 14 and are manufactured out of a resilient material. The guides 15 , 16 are movably and slidably received therein the guide tracks 14 , thus permitting the guides 15 , 16 to adjustably progress longitudinally and/or slantingly at interval adjustments as needed. Resilient stops 17 are placed within the guide tracks 14 to prevent the guides 15 , 16 from unwanted slippage down the groove track 14 , most typically fabricated with a non-slip frictional composition or mechanically affixed within the guide track 14 to accomplish the same task. The stops 17 are limiters that assist and enhance an individual's ability to quickly and consistently create cuts without slippage of the guides 15 , 16 upon operation. The stops 17 are preferably adapted to engage the guide tracks 14 at the designated position for the desired cut, thereby preventing the guides 15 , 16 from being moved an undesirable distance at an undesirable time. Therefore, the stops 17 assist in the smooth and continuous cutting operation by minimizing inadvertent guide 15 , 16 slippage. It will be appreciated that the guide tracks 14 , the guides 15 , 16 , and/or the stops 17 may be either on the front plate 11 and/or the rear plate 30 as is illustrated for comparison purposes only in FIGS. 1 and 3 .
An alternate embodiment of the present invention may disclose a clasp, locking mechanism, fastener, catch, or other detachedly affixing mechanism, mechanically situated at the opposite center side portion of the hinges 12 to fasten the plates 11 , 30 together while encompassing the siding 20 to be cut and/or trimmed.
Another alternate embodiment of the present invention may disclose other pivoting means such as a locking nut and bolt, pin, cotter pin, and/or any other sturdy pivotal affixation mechanism to meet the requirements of the functions, attributes, and features of the device 10 .
The preferred embodiment of the present invention can be utilized by the common user who has little or no training in a simple and effortless manner. After initial purchase or acquisition of the device 10 , it would be configured as indicated in FIGS. 1 through 5 .
The present invention 10 provides an easy, accurate, and safe method for properly cutting vinyl, wood, or other building siding pieces 20 during construction or renovation. The proper use of the device 10 also prevents any undesirable gouging or cracking of the siding piece 20 due to uneven and unbalanced support during the cutting process. The device 10 is anticipated to be available in multiple models and sizes to match the desired cut for most conventional and customized roof lines. Also, the device 10 provides a means for cutting siding pieces 20 with a circular saw, which provides a safe, quick, and easy cutting method.
After measuring the angles and marking the siding piece 20 , the user opens the two (2) opposing plates 11 , 30 by the hinges 12 and places the piece of siding 20 that is desired to be cut. The plates 11 , 30 are then closed, retaining the siding piece 20 therewithin, with the siding piece 20 extending outward 15 longitudinally. The straight edge guide 15 is then manipulated until the blade of a circular saw comes into contact with the siding piece 20 , taking care to ensure that both stops 17 are in place to prevent slippage of the guide 15 . The circular saw must be fitted with the proper blade to cut the particular piece of siding 20 chosen. Once the straight edge has been cut, the user moves the roof pitch edge guide 16 and stops 17 in a similar fashion to the straight edge guide 15 and proceeds to cut the desired roof pitch angle.
The foregoing descriptions of specific 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 and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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The present invention comprises an apparatus and method for accurately and safely cutting residential siding members. A specialized tool and saw guide system comprise two hingedly connected plates to securely hold and balance the siding member during the cutting process, as well as resilient saw guides for guiding a saw blade. The device allows for both a straight edge cut and an angled cut to match a conventional roof pitch. Additional embodiments are anticipated to provide for various angled cuts.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority from U.S. Application No. 61/725,429, filed Nov. 12, 2012 incorporated by reference in its entirety.
BACKGROUND
This invention relates to an intramedullary nail for use in stabilizing and enhancing the healing of broken bones, and more particularly to an intramedullary nail that includes motion along its longitudinal axis so as to elicit an improved healing response in the bone in which the nail is placed.
It is well known in the art that functional loading of skeletal bone results in changes to bone quality and quantity. Conversely, lack of mechanical loading has been found to lead to a loss of bone quality and quantity.
When a bone fractures, one of two physiological processes are stimulated that provide for healing of the fracture. The first process is denoted enchondral ossification and occurs when there is strain at the fracture site. This process forms bone through a cartilage intermediate and is similar to the mineralization that occurs at the human growth plate. The second process is denoted intramembranous ossification and occurs when the fracture edges are not only in contact and opposed but also have minimal to no strain, that is, rigid fixation. In this process, little bone callus is seen as the fracture gap is consolidated by cutting “cones” that cross the fracture. Both processes essentially bridge the gap between the fracture elements. The bony healing process in humans takes approximately 6-8 weeks except bones with potentially compromised vascular supply or vascular watershed areas (such as, for example, the tibia, scaphoid, talus, and the like). After the initial healing process, the bone is comprised of woven bone and later remodels to lamellar bone.
Typically, fractured bones are stabilized using various mechanical or surgical means to hold the fractured portions of the bone in alignment. Depending on the gap between the fracture ends, the body forms either granulation tissue (scar tissue), cartilage (enchondral ossification), or bone (intramembranous ossification). If the fracture gap is too large, the body heals via scar tissue—tough connective tissue that resists strain, and while not rigid, this tissue maintains the fragments in proximity to each other. Non-healed fractures, such as those with interposed scar tissue, can cause significant pain for the patient as there is still motion occurring between the previously fractured elements. Surgical intervention with opposition of the bones, possible use of a bone graft, and mechanical stabilization is usually necessary to help the fracture heal.
One means of stabilizing a fractured bone is through the use of an intramedullary nail. For example, where the fracture is located in the tibia bone of the lower leg, the central portion of the bone, known as the medullary canal or space, is accessed. The current convention is to ream the medullary canal prior to insertion of an intramedullary nail. In other cases, the medullary canal may not be reamed.
The intramedullary nail is inserted into the medullary canal and positioned as desired to align the fractured ends or edges of the bone and restore length, alignment, and rotation. Fixation screws, or locking screws, are usually used at both the proximal and distal ends of the nail to ensure that the intramedullary nail is a static construct with rotational stability.
Various authors have posited whether allowing some motion at the fracture site would enhance the healing process by providing mechanical signals that would initiate an anabolic response to spur bone remodeling. The problem, however, is how to allow enough motion at the fracture site to enhance the healing process while still maintaining adequate stabilization of length, alignment, and rotation of the fractured bone ends. If too much motion occurs, the bone may not completely heal.
What has been needed, and heretofore unavailable, is an intramedullary device that provides for adequate positioning and stabilization of the fractured ends or edges of a bone, while still allowing a measure of motion to occur at the fracture site to provide for enhanced healing of the fracture. The present invention satisfies these, and other needs.
SUMMARY OF THE INVENTION
In a most general aspect, the invention provides an intramedullary nail that provides for fixation and stabilization of a fractured bone while still providing a controlled amount of motion in the longitudinal axis at the fracture site to encourage and hasten bone healing.
In another aspect, the present invention includes an intramedullary nail, comprising: a distal portion and a proximal portion; a bias member or device disposed between the distal and proximal portions for biasing the distal and proximal portions apart along a longitudinal axis; and an adjusting assembly configured to engage the distal and proximal portions such that actuation of the adjusting assembly results in providing for a selected amount of motion along the longitudinal axis between the proximal and distal portions. In one alternative aspect, the distal and proximal portions are in a telescoping arrangement relative to each other.
In still another aspect, the adjusting assembly is adjustable to allow a selected amount of motion along the longitudinal axis between the proximal and distal portions of the intramedullary nail, applying a compressive force along the longitudinal axis causes a combined length of the distal and proximal portions to be reduced, and reducing the compressive force allows the combined length of the distal and proximal portions of the intramedullary nail to increase.
In yet another aspect, the invention further includes an alignment assembly that engages the proximal and distal portions of the intramedullary nail in a manner to maintain an alignment between the proximal and distal portions of the intramedullary nail.
In still another aspect, the invention also includes an outer surface of the distal and proximal portions that is covered with a material that enhances healing of a fracture. In one alternative aspect, the material is zinc.
In yet another aspect, the bias member is a spring. In an alternative aspect, the bias member is a compliant membrane.
Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side view of an embodiment of an intramedullary nail in accordance the present invention.
FIG. 1B is a cross-sectional side view of the intramedullary nail of FIG. 1A .
FIG. 1C is a magnified view of a portion of the cross-sectional side view of FIG. 1B showing details of interconnection of the distal and proximal portions of the intramedullary nail of FIG. 1A .
FIG. 2A is a side view of a distal portion of the intramedullary nail of FIG. 1A .
FIG. 2B is a cross-sectional side view of the distal portion of the intramedullary nail of FIG. 2A .
FIG. 2C is a magnified cross-sectional side view of a threaded proximal end of the distal portion of the intramedullary nail shown in of FIG. 2B .
FIG. 3A is a side view of the proximal portion of the intramedullary nail of FIG. 1A .
FIG. 3B is a cross-section of the proximal portion of the intramedullary nail of FIG. 3A showing internal details of the embodiment.
FIG. 4A is a side view of a threaded fastener used to hold the proximal and distal portions of the intramedullary nail of FIG. 1A together
FIG. 4B is a top view of the threaded fastener of FIG. 4A .
FIG. 4C is a cross-sectional side view of the threaded fastener of FIG. 4A .
FIG. 5A is a side view of a threaded fastener that may be inserted into a proximal end of the proximal portion of the intramedullary nail of FIG. 1A .
FIG. 5B is a top view looking down at the proximal end of the threaded fastener of FIG. 5A .
FIG. 5C is a cross-sectional side view of the threaded fastener of FIG. 5A .
FIG. 6A is a side view of an alternative embodiment of an intramedullary nail in accordance the present invention.
FIG. 6B is a cross-sectional side view of the intramedullary nail of FIG. 6A .
FIG. 6C is a magnified view of a portion of the cut-away view showing details of interconnection of the distal and proximal portions of the intramedullary nail of FIG. 6A .
FIG. 7A is a side view of a distal portion of the intramedullary nail of FIG. 6A .
FIG. 7B is a cross-sectional side view of the distal portion of the intramedullary nail of FIG. 7A .
FIG. 7C is a magnified cross-sectional side view of a threaded proximal end of the distal portion of the intramedullary nail shown in of FIG. 7B .
FIG. 8A is a side view of the proximal portion of the intramedullary nail of FIG. 6A .
FIG. 8B is a cross-section of the proximal portion of the intramedullary nail of FIG. 8B showing internal details of the embodiment.
FIG. 9A is a side view of an embodiment of a threaded fastener used to hold the proximal and distal portions of the intramedullary nail of FIG. 6A together
FIG. 9B is a top view of the threaded fastener of FIG. 9A .
FIG. 9C is a cross-sectional side view of the threaded fastener of FIG. 9A .
FIG. 10A is a side view of a compressible/extensible member for providing a bias between the distal and proximal portions of an embodiment of an intramedullary nail in accordance with the present invention.
FIG. 10B is a cross-sectional side view of the compressible/extensible member of FIG. 10A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, in which like reference numerals indicate like or corresponding elements among the several figures, there is shown in FIG. 1A an exemplary embodiment of an intramedullary nail 10 in accordance with the present invention. Nail 10 includes a distal portion 15 and a proximal portion 20 . As will be discussed in more detail below, the distal and proximal portions are engaged in a manner that allows each portion to move a limited amount independently of the other portion.
Distal portion 15 includes an end port 25 disposed at a distal end of the distal portion 15 . A fixation hole 30 is also disposed near the distal end of distal portion 15 . Fixation hole 30 is sized to receive a screw or other fastener that may be used to attached distal portion 15 to bone surrounding distal portion 15 when the nail 10 is positioned within the medullary space of a bone so as to fixate and stabilize a fracture in the bone.
Referring now to FIGS. 1A and 1B , a lumen 45 extends from the end port 25 through the nail 10 to a proximal end 47 of proximal portion 20 . When implanting nail 10 within a medullary space of a bone, such as, for example, but not limited to, a tibia or a femur, it is common to use a guidewire to ensure that the nail can be properly positioned, even when the medullary space may be dis-continuous due to the severity of a fracture in the bone. Lumen 45 provides for placing the nail 10 along the guidewire, and then sliding the nail 10 along the guidewire until the nail 10 is properly positioned. The guidewire may then be withdrawn from the nail 10 . The distal most end of distal portion 15 may be chamfered to provide reduced friction between the nail and the medullary space of the bone when the nail is inserted into and through the intramedullary space of the bone. The chamfer may be, for example, 15 degrees.
A threaded fastener 40 is also shown in FIGS. 1A and 1B . Fastener 40 engages threads 50 disposed in a proximal end of the proximal portion 20 of intramedullary nail 10 . Fastener 40 may be threaded into the threads in the proximal portion to provide a surgeon with a means for removing the nail 10 from the medullary space.
Referring now to FIG. 1C , as well as FIGS. 2A-C and 3 A-B, additional details of the distal and proximal portions of the nail 10 are described. A proximal end of the distal portion 15 includes a portion 60 having a reduced diameter compared to the outer diameter of the remainder of the distal portion 15 . Given this reduction in diameter, a land 65 is formed at a junction of the reduced portion 60 and the remainder of distal portion 15 . A proximal end of reduced diameter portion 60 also has a threaded portion 70 having male threads for engaging corresponding female threads 80 of adjustment nut 75 ( FIG. 1C ).
Proximal portion 20 ( FIGS. 3A-B ) includes a distal portion 115 and a proximal portion 120 . While lumen 45 extends through both portions, distal portion 115 is offset along a longitudinal axis from proximal portion 120 by an angle phi (Φ) so as to produce a bend in the nail 10 that facilitates placement of the nail through the top of the bone, for example, a tibia bone, and then down through the medullary space of the bone. This angular offset will be dependent on the bone to be stabilized. For example, a femur may require different angulation than a tibia, and thus nails to be used to stabilize a femur will have a different offset than a nail intended for use in a tibia. In one embodiment, for example, intended for implantation within a tibia bone, the angle phi may be 10 to 12 degrees, and preferable 11 degrees.
Proximal portion 120 of proximal portion 20 may also include a bore 35 sized to receive a screw or other fastener for fixing the proximal portion 120 to the portion of bone adjacent proximal portion 120 . This allows the proximal portion 20 to be fixed in such a manner to still allow for limited movement between distal portion 15 and proximal portion 20 .
As seen in FIG. 3A , the distal portion 115 of proximal portion 20 may also include a chamfered segment 125 located at a distal end 105 of distal portion 115 of proximal portion 20 . The angulation Θ of this chamfer may be, for example, 11 degrees.
Referring now FIG. 3B , proximal end 100 of proximal portion 120 of proximal portion 20 is threaded with threads 50 to receive fastener 40 ( FIG. 1A ). The diameter of lumen 45 in proximal portion 120 of proximal portion has a first diameter that may, but does not have to be, consistent throughout the length of proximal portion 120 . This diameter of lumen 45 may remain the same through the angulation between distal portion 115 and proximal portion 120 of proximal portion 20 . At some point distal to the beginning of the angulation in the segment designated 135 , the diameter of lumen 45 decreases. This reduction in diameter forms a land 82 at the junction of lumen 45 of the proximal portion and the diameter of the lumen of segment 135 . At a point distal to land 82 , the diameter of lumen 45 through segment 135 is further reduced in segment 145 , forming land 84 at the junction between the distal end of segment 135 and the proximal end of segment 145 . Finally, at a point distal to land 84 , the diameter of the lumen increases at a transition to segment 130 . This enlargement of the lumen creates land 87 at the junction between the lumen of segment 145 and the enlarged lumen of segment 130 . It will be understood that while exact dimensions of the various lumens and segments have not been specified, they may vary depending on the overall dimensions of the nail 10 and the fasteners used to join proximal portion 20 and distal portion 15 , while still providing a lumen through the entire length of the intramedullary nail 10 to allow the nail to be positioned with an intramedullary space of a fractured bone using a guidewire passing through the lumen of the intramedullary nail.
Further detail of the relationship between the various lumen diameters and segments can be understood by referring to the magnified view of FIG. 1C . This view shows how the various lumen diameters and segments of the distal portion 115 of the proximal portion 20 of intramedullary nail 10 cooperate with segment 60 of the proximal end of distal portion 15 of intramedullary 10 to provide for limited motion between the distal portion 15 and proximal portion 20 of the intramedullary nail 10 to promote bone remodeling and healing. As shown, segment 60 , including threaded area 70 extend into the lumen located at the distal end 105 of proximal portion 15 . In this configuration, a space is formed between land 65 of the distal portion 15 and land 87 of proximal portion 20 of intramedullary nail 10 . This space allows a bias means, such as a spring, to be disposed between proximal portion 20 and distal portion 15 of intramedullary nail 10 to bias the two portions apart when the spring is compressed.
Adjustment nut 75 is a threaded nut having a head 200 and a body 205 , and is shown in detain in FIGS. 4A-C . See The diameter of the body 205 is sized to be slidingly, rotationally and removably received within the lumen diameter of segment 135 of the proximal portion 115 of proximal portion 20 . Head 200 has a diameter that is larger than the diameter of body 205 , the diameter being sized to be slidably, rotatably and removably received within the lumen of area 140 , and able to pass through the angulation between proximal portion 120 and distal portion 115 of proximal portion 20 of intramedullary nail 10 . The distal edge of adjustment nut 75 , when inserted into the distal portion 20 of intramedullary nail 10 is advanced and engages threads 70 of distal portion 15 with threads 80 . A proximal end of head 200 of adjustment nut 75 includes a means 210 for engaging adjustment nut 75 so that nut 75 may be rotated in a clockwise or counterclockwise direction. Means 210 may be, for example, a hexagonally shaped indentation for receiving a suitably sized hexagonal Allen driver, or it may be slotted, or crossed, or having another suitably shaped indentation for receiving a customized driving tool.
Rotating adjustment nut 75 in a clockwise direction causes the nut to be drawing onto the threads 70 , which in turn compresses spring 85 due to the abutment of the distal edge of the head 200 of adjustment nut 75 with land 82 . Adjustment nut 75 may continue to be tightened until the spring is completely compressed, or when the distal edge of body 205 of adjustment nut 75 abuts against land 84 . Similarly, rotating adjustment nut 75 in a counter-clockwise direction will loosen adjustment nut 75 , resulting in distal portion 15 of nail 10 moving away from proximal portion 20 of nail 10 due to the bias imparted by spring 85 .
It will be understood that the threads 70 and 80 may be reversed so that rotating adjustment nut 75 in a counter-clockwise direction draws threads 70 into threads 80 to compress spring 85 , and rotating adjustment nut 75 in a clockwise direction reduces the compression of spring 85 , without departing from the intended scope of the invention.
Additionally, spring 85 is intended as a biasing member, whose function may be carried out by a variety of means besides a spring. For example, spring 85 may be replaced with a reversibly compressible material, such as a polymer. Moreover, the entire arrangement between the proximal portion 20 and distal portion 15 may be constructed in a fashion different from that described above, so long as there is a bias member or device between the two portions that may be adjusted to provide a desired amount of motion between the two portions. In an alternative embodiment, the bias member may be a compound bias member comprising a resilient polymer and a mesh of plastic, metal or other suitable material. In still another embodiment, the bias member may be a compliant membrane.
When the bias means is fully compressed, there is intended to be no relative movement between the distal portion 15 and the proximal portion 20 . Loosening adjustment nut 75 reduces the amount of compression of spring 85 , allowing for a controlled amount of longitudinal movement of the two portions relative to each other. Alternatively, the bias member may be used to put the fracture under compressing. In this embodiment, the distal portion of the nail is fixed to the bone with a screw, the proximal portion is held while the adjustment nut is tightened, so that the distal portion and proximal portions of the nail pull on the ends of the fracture.
FIGS. 5A-C illustrate details of fastener 40 . Fastener 40 has a head 250 and a threaded body 255 . The threads of threaded body 255 are sized to engage threads 50 disposed within the bore of proximal end 100 of proximal portion 20 . This allows fastener 40 to be threaded into proximal end 100 to provide a means for extracting nail 10 from a medullary space. Head 250 of fastener 40 also includes an indentation 260 shaped and sized to receive a driver, such as, for example, but not limited to, a hexagonally shaped driver, to provide for rotating the fastener 40 in clockwise and counter-clockwise directions.
In another embodiment, fastener 40 may be formed in the shape of a “handle” that has a threaded distal end and a proximal end having a handle-like shape to facilitate installation of the nail. For example, the proximal end of the handle shaped fastener may be, for example, in the shape of a “T” shape or the like. During installation, the distal end of the fastener would be threaded into the nail, and the nail placed at the entrance of the intramedullary canal. The handle shape of the proximal end of the fastener provides an area or surface which could be struck by a striking implement, and would facilitate driving the nail in the intramedullary canal of the bone. The striking implement could be, for example, a hammer, mallet or the like. The handle-like shape of the proximal end of the fastener 40 could then be used to facilitate rotation of the fastener to remove the fastener from the intramedullary nail 10 once the nail was properly positioned and stabilized within the intramedullary space of the bone.
The embodiment of the intramedullary nail described above is constructed of materials know to be biocompatible. Examples of suitable materials are various types of stainless steel or titanium alloys, such as Ti—6Al—4V, Cobalt chromium or the like.
The intramedullary nail will typically be cylindrical in shape, but may be an elongated body having another shape, such as a hexagonal, ovoid or other suitable external shape depending on the needs of the surgeon. The distal and proximal portions 15 , 20 will typically be arranged in a telescoping relationship. Moreover, a means for maintaining the proximal and distal portions 15 , 20 of intramedullary nail 10 in alignment may also be provided, such as by using a spline mounted on one of the portions to engage a keyway disposed in or on the other portion. In the case where the nail is not cylindrical, the shape of the portions may be self-aligning, such as where the overall outer profile of the nail is hexagonal.
Referring now to FIG. 6A another exemplary embodiment of an intramedullary nail 300 in accordance with the present invention is shown. Intramedullary nail 300 includes a distal portion 305 and a proximal portion 310 . As will be discussed in more detail below, the distal and proximal portions are engaged in a manner that allows each portion to move a limited amount independently of the other portion.
Distal portion 305 includes an end port 315 disposed at a distal end of the distal portion 305 . A fixation hole 320 is also disposed near the distal end of distal portion 305 . Fixation hole 320 is sized to receive a screw or other fastener that may be used to attached distal portion 305 to bone surrounding distal portion 305 when the intramedullary nail 300 is positioned within the medullary space of a bone so as to fixate and stabilize a fracture in the bone.
Referring now to FIGS. 6A-B , a lumen 345 extends from the end port 315 through the intramedullary nail 300 to a proximal end 347 of proximal portion 310 to facilitate implanting the intramedullary nail using a guidewire, as described above. The distal most end of distal portion 305 may be chamfered to provide reduced friction between the nail and the medullary space of the bone when the nail is inserted into and through the intramedullary space of the bone. The chamfer may be, for example, 15 degrees, but other angulations may be used to suit the particular bone size or fracture type into which the intramedullary nail is being implanted.
The interior of proximal end 347 of the proximal portion 310 of intramedullary nail 300 may also include threads 350 . A fastener may be threaded into the threads 350 to provide a surgeon with a means for removing the nail 300 from the intramedullary space of the bone.
Referring now FIG. 6C , as well as FIGS. 7A-C and 8 A-B, additional details of the distal and proximal portions of the nail 300 are described. A proximal end of the distal portion 305 of nail 300 includes a portion 360 having a reduced diameter compared to the diameter of the remainder of the distal portion 305 . Given this reduction in diameter, a land 361 is formed at a junction of the reduced portion 360 and portion 362 . Portion 362 has an increased diameter relative to portion 360 , but that diameter is less than the outer diameter of distal portion 305 . The junction between portion 362 and the remainder of distal portion 305 thus forms a land 365 . A proximal end of portion 360 also has a threaded portion 370 having male threads for engaging corresponding female threads 380 of adjustment nut 375 ( FIG. 6C ).
Proximal portion 310 ( FIGS. 8A-B ) includes a distal portion 415 and a proximal portion 420 . While lumen 45 extends through both portions, distal portion 415 is offset along a longitudinal axis from proximal portion 420 by an angle phi 2 (Φ 2 ) so as to produce a bend in the nail 300 that facilitates placement of the nail through the top of the bone, for example, a tibia bone, and then down through the medullary space of the bone. This angular offset will be dependent on the bone to be stabilized. For example, a femur may require different angulation than a tibia, and thus nails to be used to stabilize a femur will have a different offset than a nail intended for use in a tibia. In one embodiment, for example, intended for implantation within a tibia bone, the angle phi 2 may be 10 degrees.
As is evident from FIGS. 8A-B , besides major sections portion 415 and portion 420 , proximal portion 310 may include additional segments, such as segment 450 , 455 , 460 , 465 , 470 , 475 and 480 . The geometric shape of these segments may be consistent with the shapes of portions 415 and 420 , or they may be varied to facilitate use of the intramedullary nail 300 . In the embodiment shown, for example, segment 450 , which forms the most proximal segment of portion 420 of intramedullary nail 300 may be a cylinder having a constant outer diameter, but also may have a chamfer disposed on the proximal end 400 of segment 450 . This chamfer ensures that once the nail is implanted in a bone, the proximal end of the nail will not unduly extend from the top of the bone, but will instead more readily blend with the contour of the bone.
As shown in FIG. 8A , segment 455 may have a proximal end that has an outer diameter substantially equal to the outer diameter of the distal end of segment 450 . The outer diameter of segment 455 tapers along its length to a reduced outer diameter at its distal end. The taper may be, for example, but not limited to, five degrees.
In some embodiments, such as the embodiment of FIG. 8A , proximal portion 310 may also include a segment 460 . This segment may have a consistent outer diameter, beginning at the distal end of segment 455 and ending at the proximal end of segment 465 , or the outer diameter may change depending on the design of the nail.
Segment 465 includes angulation phi 2 , as described above. There may also be a segment 480 interposed between segment 470 and segment 465 . The length and outer diameter of this segment are dependent upon the over length of the nail and the design requirements as described above.
Segment 470 may also be included. As shown, segment 470 may taper from its proximal end to its distal end, as required for the design of the nail. In the example shown, the taper is two degrees. Segment 475 comprises the distal end of proximal portion 310 .
It will be understood by those skilled in the art that the various segments described above may or not be present in an embodiment of the intramedullary nail of the present invention. For example, depending on the length of the nail, one or both of segments 460 and 480 may be omitted without departing from the scope of the invention. Additionally, segments 470 and 455 may be need to be tapered, and indeed, may be omitted from the nail, depending on the design of the nail for a particular bone size or length or fracture situation.
Proximal portion 420 of proximal portion 310 may also include a bore 325 sized to receive a screw or other fastener for fixing the proximal portion 420 to the portion of bone adjacent proximal portion 420 . This allows the proximal portion 420 to be fixed in such a manner to still allow for limited movement between distal portion 305 and proximal portion 310 .
Referring now FIG. 8B , proximal end 400 of proximal portion 310 is threaded with threads 350 to receive a fastener or handle-like tool as described above to facilitate installation and removal of intramedullary nail 300 from the intramedullary space of a bone. The diameter of lumen 345 in proximal portion 420 of proximal portion 310 has a first diameter that may, but does not have to be, consistent throughout the length of proximal portion 420 . This diameter of lumen 345 may remain the same through the angulation between distal portion 415 and proximal portion 420 of proximal portion 310 .
At some point distal to the beginning of the angulation in the segment designated 535 , the diameter of lumen 345 decreases. This reduction in diameter forms a land 382 at the junction of lumen 345 at the proximal end of segment 545 and the diameter of the lumen at the distal end of segment 135 . The diameter of lumen 345 increases at junction between the distal end of segment 545 and the proximal end of segment 530 . This change in lumen diameter results in the formation of a land 387 .
It will be understood that while exact dimensions of the various lumens and segments have not been specified, they may vary depending on the overall dimensions of the nail 300 and the fastener used to join proximal portion 310 and distal portion 305 , while still providing a lumen through the entire length of the intramedullary nail 300 to allow the nail to be positioned with an intramedullary space of a fractured bone using a guidewire passing through the lumen of the intramedullary nail.
Further detail of the relationship between the various lumen diameters and segments can be understood by referring to the magnified view of FIG. 6C . This view shows how the various lumen diameters and segments of the distal portion 415 of the proximal portion 310 of intramedullary nail 300 cooperate with area 360 of the proximal end of distal portion 305 of intramedullary 300 to provide for limited motion between the distal portion 305 and proximal portion 310 of the intramedullary nail 300 to promote bone remodeling and healing. As shown, area 360 includes threaded area 370 extends into the lumen located at the distal end 405 ( FIG. 8A ) of proximal portion 310 . In this configuration, a space is formed between land 365 of the distal portion 305 and land 387 of proximal portion 310 of intramedullary nail 300 . This space allows a bias means, such as a spring, to be disposed between proximal portion 3100 and distal portion 305 of intramedullary nail 300 to bias the two portions apart when the spring is compressed.
Adjustment nut 375 is a threaded nut having a proximal end 600 , a distal end 605 , and a body 610 , and is shown in detail in FIGS. 9A-C . The diameter of the body 615 is sized to be slidingly, rotationally and removably received within the lumen diameter of segment 535 of the proximal portion 415 of proximal portion 310 , and is able to pass through the angulation between proximal portion 420 and distal portion 415 of proximal portion 310 of intramedullary nail 300 . In this embodiment, the outer diameter of body 610 is constant from proximal end 600 to distal end 605 , although some deviation may be allowed so long as the adjustment nut 375 is able to slide through lumen 345 .
Adjustment nut 375 , when inserted into the distal portion 305 of intramedullary nail 300 engages threads 370 of distal portion 305 with threads 380 . The proximal end of adjustment nut 375 , as shown in FIG. 9B , includes a means 615 for engaging adjustment nut 375 so that nut 375 may be rotated in a clockwise or counterclockwise direction with a suitable tool. Means 615 may be, for example, a hexagonally shaped indentation for receiving a suitably sized hexagonal Allen driver, or it may be slotted, or crossed, or having another suitably shaped indentation for receiving a customized driving tool.
Rotating adjustment nut 375 in a clockwise direction causes the nut to be drawing onto the threads 370 , which in turn compresses spring 385 due to the abutment of the distal end 605 of adjustment nut 375 with land 382 . Adjustment nut 375 may continue to be tightened until the spring is completely compressed. Similarly, rotating adjustment nut 375 in a counter-clockwise direction will loosen adjustment nut 375 , resulting in distal portion 305 of nail 300 moving away from proximal portion 310 of nail 300 due to the bias imparted by spring 385 .
It will be understood that the threads 370 and 380 may be reversed so that rotating adjustment nut 375 in a counter-clockwise direction draws threads 370 into threads 380 to compress spring 385 , and rotating adjustment nut 375 in a clockwise direction reduces the compression of spring 385 , without departing from the intended scope of the invention. As described above, while bias means is shown as spring 375 in this embodiment, other biasing devices or materials may be utilized, such as a reversibly compressible polymer, and the like.
FIGS. 10A-C illustrate one embodiment of a biasing device or means 700 that may be used with the various embodiments of the present invention. In this embodiment, the biasing means 700 is depicted as a spring. As noted above, however, other types of biasing members or devices or means may be employed. Where a spring is used, the coils of the spring may be consistent, or the spring may be formed in such a way that the spring constant K of the spring varies along the length of the spring, thus imparting variable biasing force depending on how much the spring is compressed or extended. This variance may be accomplished in various way, as is known to those skilled in the art. For example, the spacing between coils of the spring may differ along the longitudinal length of the spring, or the diameter of the coil wire may vary.
In still another embodiment, the size and/or resiliency of the bias member may be selected depending on bone size and patient weight to achieve a desired load-deflection. Different bias members could have different load-deflection curves, allowing a surgeon to choose the bias member that fits a particular situation, including fracture type, complexity, patient weight and bone dimensions.
In yet another embodiment, any of the various embodiments of the nail of the present invention may be covered or coated with a suitable biocompatible material which may have healing enhancement properties. The nail may be coated with, for example, but not limited to, zinc. Alternatively, the nail may be coated with a material or drug, or a combination of material or drug, to enhance bone formation or to promote healing of the fracture. In still another embodiment, the outer surface of the nail of any of the various embodiments may be textured to enhance implantation, or hold a coating or drug or combination of the two to enhance healing of the fracture.
Various procedures for using an intramedullary nail of the present invention are described in the literature and are well known in the art. For example, an method for reducing a tibial shaft fracture is contained in Trafton, Peter G. “Tibial Shaft Fractures.” (Elsevier Science (USA) 2003), the entirety of which is intended to be incorporated by reference herein.
Other information discussing the scientific rationale supporting the advancement over the prior art represented by the inventors various embodiments of the present invention are also attached hereto, and are intended to be incorporated in their entirety by reference herein.
While several particular forms of the invention have been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention.
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An intramedullary nail for fixation and stabilization of a fractured bone that also allows for a controlled amount of longitudinal motion at the fracture site to encourage bone remodeling and healing is described. The intramedullary nail has a proximal portion and a distal portion that are coupled together in a manner by a biasing assembly that provides for a controlled movement of the proximal and distal portions relative to each other so that when a patient puts pressure on the bone, such as when walking, the fracture site compresses and the bone ends move together, and when the pressure is released from the bone, the bone ends are biased apart by a controlled amount.
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BACKGROUND OF THE INVENTION
This invention was made in the course of or under a contract or subcontract thereunder with the Office of Naval Research.
Field-effect transistors have been known for some time in which the transistor was formed by producing source, gate, and drain electrodes on the face of a thin active layer supported on an insulative substrate. While these prior art field-effect transistors (FET's) have had satisfactory performance in a variety of applications, their high frequency and high power application has been somewhat limited by the physical dimensions of the device, occasioned by the necessity to provide adequate spacing between the three electrodes, resulting in a certain minimum channel length from source to drain. The physical dimensions of the device establish an upper cutoff frequency through transit time and capacitance effects, while channel resistance limits the power handling capability of the device.
SUMMARY OF THE INVENTION
The present invention reduces the long, highly resistive channel and lowers transit time and capacitance by positioning the gate electrode on the opposite side of the active layer from the source electrode. When this has been done, it is possible to position the gate and source electrodes much closer together than was possible in the prior art. For example, the gate and source electrodes may be partially overlapping on the active layer or at least may be positioned such that their adjacent edges are aligned. When this has been done, as can readily be appreciated, the distance from the gate to the source is substantially reduced as compared with the situation which is possible when these two electrodes are mounted on the same face of the active layer, (i.e. co-planar). The channel length from source to drain is also reduced. Thus, the high frequency performance and channel resistance are both improved.
It is a principal object of the invention to provide an FET having improved high frequency performance.
It is an additional object of the present invention to provide an FET having a reduced channel resistance.
It is a further object of the present invention to provide an FET in which the gate and source electrodes are mounted on opposite faces of the active layer.
It is a further object of the present invention to provide an FET in which the adjacent edges of the gate and source electrodes are aligned.
These and other features, objects and advantages of the present invention will become clear from reading the following detailed description of a preferred embodiment and studying the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of a prior art planar FET.
FIG. 2 is a sectional side view of a non-coplanar FET according to the present invention.
FIG. 3 is a sectional side view of an FET having a source contact extending through the substrate according to the present invention.
FIG. 4 is a sectional side view of a plural-element FET with a common source electrode according to the present invention.
FIG. 5 is a mixed process- and-product drawing including sectional side views of several intermediate products at various stages in the fabrication of a device similar to FIG. 2.
FIG. 6A, and FIG. 6B, which is a continuation of FIG. 6A, together comprise a mixed process-and-product drawing including sectional side views of several intermediate products in the fabrication of an FET similar to that of FIG. 3.
FIG. 7 is a mixed process-and-product drawing including sectional side views of several intermediate products in the fabrication of an FET similar to the one shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a prior art planar FET 11 having a chromium-doped or oxygen-doped relatively insulating GaAs substrate 13 upon which is epitaxially grown a thin active layer 15 of N-doped GaAs, for example. By well known processes such as the formation by photolithography and subsequent etching of a silicon dioxide mask, source 17, gate 19 and drain 21 electrodes are formed on the surface of the active layer 15. Source 17 and drain 21 are ohmic contacts and Gate 19 is a Schottky barrier (rectifying) contact as is well known.
FIG. 2 illustrates a preferred embodiment of the present invention in which the FET 11' consists of a chromium-doped or oxygen-doped relatively insulating gallium arsenide substrate 12, a thin (0.2 to 1 micron, for example) active layer of epitaxial n-type GaAs 15' and a supporting dielectric substrate 13' which might be, for example, a transparent borosilicate glass. However, in accordance with the present invention, source electrode 17' and gate electrode 19' are no longer coplanar as in the prior art. In particular, source electrode 17' is located on the underside of active layer 15' whereas gate electrode 19' remains on the top surface thereof. Drain electrode 21' has also been illustrated on the undersurface of active layer 15' but could be located on the same (top) surface as gate 19'.
FIG. 3 illustrates an FET 11" of the same general type as illustrated in FIG. 2 having a chromium- or oxygen-doped relatively insulating gallium arsenide substrate 12', a thin (0.2-1 micron for example) active layer of epitaxial n-type GaAs 15" and a supporting dielectric substrate 13" which might be for example, a transparent borosilicate glass. Source 17", gate 19", and drain 21" are arranged on active layer 15" as in FIG. 2. However in accordance with another aspect of the invention a large thermally and electrically conductive contact 23 extends from source electrode 17" through gallium arsenide substrate 12' and dielectric substrate 13". Conductive contact 23 has its upper surface in contact with source electrode 17", and may be fully coextensive with source 17".
FIG. 4 illustrates an embodiment of the present invention in which a substrate of n+ GaAs 13'" serves also as a source electrode for the FET. Substrate 13'" has large area and high thermal and electrical conductivity. As illustrated the FET of FIG. 4 is a multi-element structure having a common source electrode and plural discrete gate and drain electrodes 19'" and 21'" respectively.
As already noted, substrate 13'" made of n+ GaAs serves as a common source electrode for all of the gates and drains 19'" and 21'". Since substrate 13'" is in close contact over its entire surface with the active layer 15'" of the device, it is necessary to provide that those surface portions of substrate 13'" which are directly opposite the gates and drains 19'" and 21'" be rendered relatively insulative in order for the device to function as an FET.
Accordingly relatively insulative surface portions 25 are provided on the surface of substrate 13'" directly opposite each of the gate and drain electrodes. Although, in FIG. 4, insulative surface portions 25 have been shown as having a considerable depth, it is only necessary that a very thin surface portion of substrate 13'" be rendered insulative in order for the device to function satisfactorily. The actual depth or thickness of insulative portions 25 will vary according to the method of fabricating them as will appear infra.
FIG. 5 details the steps in a process which could be used to form the FET of FIG. 2. The operations illustrated in the method of FIG. 5 are not the only way to form FET's of the type shown in FIG. 2, but will result in the realization of that structure using a sequence of operations which are in themselves within the skill of competent semiconductor fabrication technologists. In order to aid in understanding the process a series of intermediate products are shown in alignment with the stage of the process where they occur. Dotted lines connecting the process flow line to the intermediate products show exactly where the product occurs.
In FIG. 5 an AlGaAs layer is epitaxially grown on the surface of a GaAs substrate, followed by an n- GaAs layer approximately 0.2 - 1 micron thick which will form the active layer 15' for the device. An Si-O 2 masking layer is deposited, photolithographed and etched to form the mask for growing the S and D electrodes. These electrodes are then grown from epitaxial n+ GaAs and the SiO 2 mask is etched away in HF etchant.
A small lead contact area (not shown) on each S and D electrode is metallized for later attachment of a lead wire. These contact areas are then masked with SiO 2 , and insulating layer 12 of chromium- or oxygen-doped GaAs is grown over active layer 15' and the unmasked areas of source electrode 17' and drain electrode 21'. A dielectric substrate which could be for example a borosilicate glass is bonded to the surface of the chromium-doped gallium arsenide layer.
After suitably masking the edges of the wafer, the gallium arsenide substrate is removed with an NH 4 OH - H 2 O 2 etchant, followed by removal of the AlGaAs layer in a buffered HF etchant. The wafer is then inverted and an SiO 2 masking layer is deposited over active layer 15' followed by photolithography and etching for gate electrode 19'. A rectifying gate electrode is formed by known techniques and the SiO 2 mask is etched away in buffered HF. Subsequently the dielectric substrate is photolithographed and etched to form channels in alignment with the contact areas of the S and D electrodes and connections are made to these electrodes as, for example, by ultrasonically welding fine wires thereto.
As shown in FIG. 6, an FET similar to that shown in FIG. 3 can be formed by first growing AlGaAs on a GaAs substrate and then epitaxially growing n-GaAs active layer 15" approximately 0.2 - 1 micron thick on the surface of the AlGaAs. Then an SiO 2 masking layer is formed over the surface of active layer 15" and photolithography and etching are carried out to form a mask for source and drain electrodes 17" and 21" respectively. These electrodes are then formed by epitaxially growing n+ GaAs followed by etching in buffered HF to remove the SiO 2 mask.
A small contact area of the surface of drain electrode 21" is metallized and, typically the entire surface of S electrode 17" is metallized. A masking layer of SiO 2 is formed over the surface of the wafer, and photolithography and etching are carried out, leaving SiO 2 covering only the metallized portions of source electrode 17" and drain electrode 21". Chromium- or oxygen-doped GaAs layer 12' is epitaxially grown over the surface of the wafer except in those areas covered by the SiO 2 masking.
The SiO 2 mask is removed and a conductive contact is metallized from the surfce of source electrode 17" to the surface of insulating GaAs layer 12'. A dielectric substrate which might be a borosilicate glass is bonded to the surface of layer 12' and, by photolithography and etching, a hole in registry with source electrodes 17" is formed. By further metallizing the conductive contact is extended to the surface of the dielectric substrate.
As in FIG. 5 the GaAs substrate and the AlGaAs layer are successively etched with suitable masking to protect the edges of the wafer. The wafer has been inverted and, by SiO 2 masking followed by photolithography and etching, a window for gate electrode 19" is formed in desired alignment with source electrode 17". Gate electrode 19" is formed as a rectifying contact in the window in the SiO 2 masking layer. The masking layer is then removed by etching in buffered HF, and photolithography and etching are carried out to produce a channel through dielectric substrate 13" in alignment with the contact area of drain electrode 21". Subsequently ohmic connection is established to drain electrode 21" by, for example, ultrasonically welding a fine wire lead thereto.
In FIG. 7 is shown a method for fabricating the device of FIG. 4. Starting with an n+ gallium arsenide substrate (13'" in FIG. 4) an SiO 2 masking layer is deposited and photolithography and etching in buffered HF are used to form windows for relatively insulative surface portions 25. Then substrate 13'" is etched using an NH 4 OH - H 2 O 2 etchant to a depth of 5-10 microns, for example. Chromium- or oxygen-doped GaAs is then grown in the windows of the n+ GaAs substrate 13'" forming insulating surface portions 25. The SiO 2 masking layer is etched away and epitaxial n GaAs active layer 15'" is formed to a depth of for example, 0.2 - 1 micron over the surface of subtrate 13'". An SiO 2 masking layer is formed over active layer 15'" and photolithography and etching are carried out to produce windows for gate electrodes 19'" and drain electrodes 21'". Finally ohmic drain electrodes 21'" and rectifying (Schottky-type barrier) gate electrodes 19'" are formed. The SiO 2 masking layer is then etched away in buffered HF, and the device 11'" is ready for incorporation into a finished product.
It is to be noted, in accordance with the present invention, that insulative surface portions 25 need not be formed by etching recesses in the surface of n+ GaAs substrate 13'" and subsequently epitaxially growing chromium- or oxygen-doped GaAs in these recesses. It is equally possible to use other treatments such as, for example, high energy proton bombardment to render surface portions 25 non-conducting. Accordingly it may or may not be necessary depending upon the particular technique chosen to utilize an SiO 2 masking layer and to etch recesses for the deposition of insulative surface portions 25.
As can readily be appreciated fabrication of the device of FIG. 4 as detailed in FIG. 7 is considerbly simpler than fabrication of either of the devices of FIG. 2 or FIG. 3 (FIGS. 5 and 6, respectively). Moreover the device of FIG. 4 has certain inherent advantages in operation. The common lead inductance ordinarily produced by bonding source electrode to ground plane is nonexistent since the source is the substrate itself which can be directly bonded to a ground plane. Thermal resistance can be small by the use of a thin n+ substrate. An additional advantage is that the active layer 15'" is grown directly onto a GaAs substrate instead of onto an intermediate layer of AlGaAs resulting in optimum lattice matching, mobility and mechanical support. Contact resistance between source electrodes and the active layer 15'" is drastically reduced because of the N+ to N semiconductor contact between substrate 13'" and active layer 15'", requiring no metal-to-n-type ohmic contact.
Since many changes could be made in the inventive embodiments described without departing from the true scope of the invention it is intended that that scope be interpreted only from the following claims.
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By positioning the source and gate electrodes on the opposite faces of the active layer, these electrodes can be brought closer together and may have their adjacent edges mutually aligned or even overlapping. The series source resistance and channel resistance can be greatly reduced, because of this closer spacing, which can not be attained when the electrodes are coplanar. By also locating the drain electrode on the same side of the active layer as the source, the source-to-drain spacing can be significantly reduced, reducing channel length and improving the high frequency performance of the transistor. Further, because the electrodes are located on both sides of the active layer, it is possible to provide a large area contact on the bottom, or substrate, side of the epitaxial wafer structure which can advantageously be used to provide a low thermal and electrical resistance connection for the source contact, for example. Finally, the fact that one or more of the electrodes can be contacted from the bottom of the wafer makes possible the simple parallel interconnection of electrodes to easily form multiple element power transistors.
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RELATED APPLICATIONS
The present application claims the benefit of provisional patent application Ser. No. 61/107,833 filed Oct. 23, 2008 entitled “Method and Apparatus for Soil Excavation using Supersonic Pneumatic Nozzle with Wear Tip and Supersonic Nozzle with Wear Tip for use therein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to soil excavation using supersonic nozzles, in particular to a method and apparatus for soil excavation using supersonic pneumatic nozzle with wear tip and supersonic pneumatic nozzle with wear tip for use therein.
2. Background Information
U.S. Pat. No. 5,782,414, which is incorporated herein by reference, notes that it has been well known that compressed air released in close proximity to and directed toward the ground can result in loosening of a number of types of soil. A pneumatic soil excavation tool, also called a wand, consisting of a valve, length of pipe or tubing, and ending in a reduced sized nipple or nozzle, supplied with air from a standard portable compressor, is commonly used for the purposes of dislodging soil safely from around underground utilities such as gas, water, or sewer pipes and electric, telephone, television, or other cables. The compressed air does not pose a hazard of damaging the buried utility as does a pick, digging bar, spade, bucket, or blade.
The ability to unearth safely other types of buried objects is also important. For example, in the industrial or nuclear energy sectors, such objects include glass bottles, cardboard or wood boxes, metal or fiber drums, or metal cylinders of chemical or radioactive waste. From the military sector, objects include all types of unexploded ordnance or chemical munitions.
A number of tools have been marketed produce an air stream for improved digging purposes by making the air exit the tool at a supersonic speed. For example, U.S. Pat. No. 4,813,611, which is incorporated herein by reference, discloses a compressed air nozzle for use in soil excavation to uncover buried pipes, electrical cables and the like. U.S. Pat. No. 5,170,943 discloses a similar tool with a handle, valve, electrically insulating barrel, and a nozzle. The '943 patent includes a conical shield to protect the operator, but nothing to protect the nozzle. U.S. Pat. No. 5,212,891 discloses a further excavating pneumatic nozzle design.
Air excavation nozzles should not be confused with the rocket nozzles. Supersonic air excavation nozzles used for excavation purposes are different than rocket nozzles in a number of important ways. Supersonic air nozzles for earth excavation operate at significantly lower pressures and temperatures than rocket nozzles. For example, a rocket's chamber pressure may reach 1,000 to 3,000 psig and the exhaust gas temperature may be 1,800° to 7,700° F., while typical gas jet excavation nozzles operate at around 100 to 200 psig and at 80° to 140° F. The velocity of the exhaust gas exiting from a chemical rocket's nozzle may be from 6,000 to 14,000 ft/sec; while for an excavation nozzle typical values are from 1,700 to 2,000 ft/sec. The specific nozzle profile for a typical rocket nozzle is, thus, significantly different in shape than for an air excavation nozzle.
U.S. Pat. No. 6,845,587 describes the practices of revival woody plants that are in decline, which is usually preferred to replanting. Revival avoids costs for removal and additional costs for replacement. Typically, revival has meant either aggressively fertilizing the subject plant and/or loosening the soil. Revival success is dependent on the degree of soil compaction and existing moisture content. Earlier methods include laboriously exposing roots using trowels and small digging implements. Once exposed, the roots were reburied with new loose soil or covered with the existing soil now more loosened. This early, labor intensive method is similar to the way archeologists dig for shards of pottery—slow and tedious. An improvement over manual excavation is a vertical mulching technique where a grid of 1 to 2 inch holes is drilled in the rooting soil. The holes are then backfilled with porous material and/or fertilizer.
One technique of soil loosening uses compressed air. Compressed air released at supersonic speed fractures the soil, with minimal damage to roots. Unlike porous soil, non-porous matter, such as roots, remain minimally damaged by the compressed air. Soil fracturing avoids the problems of mechanical excavation.
Fracturing soil by using compressed air is popularly used on lawns and turfs, such as golf courses. To maximize efficiency compressed air is injected in a grid. The grid is spaced so to aerate the soil evenly throughout a specified area by fracturing the soil.
Specifically U.S. Pat. No. 6,845,587 provides for the provision of a method of improving the rooting soil of a woody landscape plant comprising the steps of exposing a root collar of a plant; defining a first improvement zone encompassing the root plate area; excavating the first improvement zone with an air excavator; and adding a beneficial treatment to the first improvement zone.
The above description illustrates the growing applications for pneumatic supersonic soil excavation tools. However, the observation and analysis of damage to the exterior of various supersonic nozzles, particularly the relatively rapid failure of nozzles used during excavation of the ground, has demonstrated a need for improvement. The damage to the nozzle exterior is best described as erosion, presumably as the result of back flow of hard particles in the soil that impact the nozzle exterior with sufficient velocity and hardness to wear away (erode) the nozzle exterior. This blow back does not erode the nozzle expansion exit because the air jet coming from the nozzle expansion exit is the highest velocity in the nozzle region, and any nearby rebounding air/particles are simply drawn into the exiting air stream before it/they can reach the nozzle expansion exit. But the backflow air, when it contains sufficiently hard particles, and sufficient velocity, can and will erode the nozzle exterior.
The supersonic exit stream from the nozzle begins losing velocity, and thus digging effectiveness, as soon as the stream leaves the nozzle exit. Thus the typical digging function is performed by placing and keeping the nozzle exit, as close as possible, to the ground being excavated. This, of course, also keeps the nozzle exterior as close as possible to any high velocity back flow or blow back. When this back flow contains particles of sufficient hardness to erode any typical metal, such as stainless steel, anodized aluminum, brass etc., it is a matter of relatively brief time (e.g., days or weeks) to nozzle failure.
Experience shows that materials as hard as ordinary sand are very effective in eroding metals. Consequently this effect may also be termed as “reverse sand blasting”. The inventors of this application have experienced that this effect is seen at its worst when working in sand, in places such as middle eastern desserts. However the effect is perceptible in any soil that has sufficient content of such hard particles. Thus the occurrence and extent of the problem is difficult to predict. For, example the inventors of this application have also experienced this reverse sandblasting nozzle failure effect when working with air excavation tools in areas such as Ohio, many miles from the nearest large body of water, where one might ordinarily expect sandy beaches. Many geologic conditions can lead to soils containing small hard particles, similar to sand. An example is long term wind or water erosion of rock. It is believed that any hard particles in the soil will increase the reverse sand blasting effect on the nozzle.
Typical supersonic nozzle designs, as evidenced in the above cited patents usually focus on the interior of the nozzle design, in part because of the difficulty of these designs, and their tendency to be sophisticated, and the exterior has been left to the casual discretion of the designer. In some cases, the exterior design has been the subject of design patent protection, see for example U.S. Design Pat. No. D408,830, while there has been a functional need for a more utilitarian approach to nozzle exterior construction lurking in the soil.
FIG. 1 is a reproduction of an isometric figure from issued U.S. Design Pat. No. D408,830 and is an accurate representation of a commercially available air excavation nozzle that has been used for many years as the exterior of a supersonic nozzle used in excavation. This nozzle design is emblematic of the undesirable characteristics that the present invention solves. The integral nozzle tip outside diameter is smaller then the body of the nozzle, which exposes that nozzle body to reverse sand blasting erosion. This resulting nozzle body flat presents a perfect reverse sand blasting target. A similar perfect target is presented at the exterior end of the wrench flats that precede the trailing balance of the nozzle body. Further, the rear end of this nozzle is blunt, thereby presenting a likely snagging surface as the nozzle is withdrawn from soil.
FIGS. 2A and 2B illustrate a commercially available prior art supersonic pneumatic nozzle that was put in service with out any of the protective features of the present invention. The nozzle was used in shallow trenching in sandy soil. The nozzle tip was integral with the nozzle body. The extent of the actual reverse sand blasting erosion to the wear tip and the nozzle is illustrated by tightly spaced shading. This erosion was sufficiently severe within a month to carry the erosion through the nozzle exterior into the nozzle interior, near the nozzle entrance, as shown. In other words, nozzle failure occurred within a month of active service in a sandy environment.
It is an object of the present invention to provide a supersonic air excavation nozzle that alleviates at least some of the above stated problems associated with reverse sand blasting.
SUMMARY OF THE INVENTION
The above object is achieved with the embodiments according to this invention, which include is a supersonic pneumatic nozzle assembly with a wear tip formed of an especially hard, erosion resistant material. The erosion or wear resistant material may be carbide material such as Cerbide™ material (a polycrystalline tungsten carbide), any cemented carbide, or carbide(s), of boron, titanium, tungsten or other highly wear resistant formulations. The nozzle body and the wear tip of the nozzle assembly are both generally cylindrical in exterior shape, and where an outside diameter of the wear tip is (1) approximately equal to or larger than any external diameter of the nozzle body, or otherwise shadows all of the nozzle body exterior; or (2) includes a leading edge deflecting surface to deflect “reverse sandblasted particles” away from the nozzle body, or (3) both. When such a nozzle assembly is used for excavation, the purpose of this structure is to resist the action of high velocity air, rebounding from the ground with entrained hard particles that can erode the nozzle body exterior, thus leading to nozzle assembly failure.
One aspect of the invention can be described as providing a pneumatic nozzle assembly comprising a nozzle body having an internal through passage with inlet on the a first side and an outlet on an opposed side of the nozzle body; and a replaceable cylindrical wear tip removably coupled to the nozzle body and with an internal through passage aligning with the outlet of the nozzle body, and wherein an outside form of the wear tip is configured to direct reverse sand blasting particles away from the external surfaces of the nozzle body.
The invention may provide that the nozzle body is a converging-diverging cylindrical nozzle body having the inlet on the converging side and the outlet on the diverging side of the nozzle body; and wherein an outside diameter of the wear tip is greater than or equal to any external diameter of the nozzle body to direct reverse sand blasting particles away from the external surfaces of the nozzle body. The outside diameter of the wear tip may, in one embodiment, be greater than the external diameter of the nozzle body along a first section of the wear tip beginning at the end of the wear tip opposed from the nozzle body, and with the wear tip further including a smooth transitional shape from a widest part of the wear tip to a distal end of the nozzle body to minimize snagging of the nozzle assembly on buried objects in use.
The invention may provide that the internal through passage of the wear tip aligning with the outlet of the nozzle body has a diameter substantially equal to or larger than the outlet at a position adjacent the outlet. Further the invention may provide that the interior of the wear tip, closest to the nozzle body outlet, is sufficiently close to the physical inside diameter of the nozzle body outlet, whereby any rebounding air stream carrying hard particles from the ground being excavated is readily drawn into the exiting supersonic jet and ejected. The invention may provide that the internal through passage of the wear tip aligning with the outlet of the nozzle body has diverging shape such that any rebounding air stream carrying hard particles in that region from the ground being excavated is directed towards the exiting air jet.
The invention may provide an intermediate adaptor attached to the nozzle body to facilitate removable attachment to the nozzle body.
The invention may provide that the nozzle body is a converging-diverging cylindrical nozzle body having the inlet on the converging side and the outlet on the diverging side of the nozzle body; wherein a largest outside diameter of the wear tip is less than the external diameter of the nozzle body, wherein the wear tip includes a leading end of the wear tip beginning opposite of the nozzle body which is outwardly tapered from the distal end of the wear tip toward the nozzle body to direct reverse sand blasting particles away from the external surfaces of the nozzle body.
Another aspect of the invention provides a method of soil excavation comprising the steps of: providing a pneumatic nozzle assembly comprising a converging-diverging nozzle body having an internal through passage with inlet on the converging side and an outlet on the diverging side of the nozzle body, and a wear tip removably coupled to the nozzle body and with an internal through passage aligning with the outlet of the nozzle body; and directing reverse sand blasting particles away from the external surfaces of the nozzle body through the use of the wear tip. The invention may provide the step of providing supersonic flow from the pneumatic nozzle.
The method of soil excavation of claim 18 wherein an outside diameter of the wear tip is greater than or equal to any external diameter of the nozzle body to direct reverse sand blasting particles away from the external surfaces of the nozzle body.
An alternate embodiment of the present invention is similar, but uses any typical metal for either or both the pneumatic nozzle body and the wear tip, with provision of a wear tip outside diameter that exceeds any outside diameter of the nozzle body to provide sacrificial and temporarily protective material for the nozzle body, plus a suitable wear tip forward extension.
These and other advantages of the present invention will be clarified in the description of the preferred embodiments taken together with the attached drawings in which like reference numerals represent like elements throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages appear in the following description and claims. The enclosed drawings illustrate some practical embodiments of the present invention, without intending to limit the scope of the invention or the included claims.
FIG. 1 is a perspective view of a prior art soil excavating supersonic pneumatic nozzle assembly;
FIG. 2A is a section elevation side view of a prior art soil excavating supersonic pneumatic nozzle assembly;
FIG. 2B is a cross-sectional view of the prior art nozzle assembly of FIG. 2A taken along line 2 B- 2 B of FIG. 2A and wherein section line 2 A- 2 A illustrates the section line for FIG. 2A ;
FIG. 3A is a section elevation side view of a soil excavating supersonic pneumatic nozzle body and wear tip according to one embodiment of the present invention;
FIG. 3B is a cross-sectional view of the nozzle of FIG. 3A , wherein line 3 A- 3 A illustrates the section line for FIG. 3A ;
FIG. 4A is a section elevation side view of a soil excavating supersonic pneumatic nozzle body and wear tip according to another embodiment of the present invention;
FIG. 4B is a top end view of the nozzle body of FIG. 4A , wherein line 4 A- 4 A illustrates the section line for FIG. 4A ;
FIG. 4C is an exploded section elevation side view of the nozzle body and wear tip of FIG. 4A ;
FIG. 5A is a section elevation side view of a soil excavating supersonic pneumatic nozzle body and wear tip according to another embodiment of the present invention; and
FIG. 5B is a top end view of the nozzle body of FIG. 5A , wherein line 5 A- 5 A illustrates the section line for FIG. 5A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a view of a prior art nozzle assembly of the prior art as shown in Design patent D408,830 and is representative of a commercially available nozzle design. This prior art figure also illustrates most of the failures with use existing pneumatic nozzle assembly designs for supersonic soil excavations that are addressed by this invention. The prior art nozzle exit 15 of this prior art nozzle assembly design is so close to the integral wear tip leading surface 16 , that this prior art wear tip leading surface 16 , will be worn away, much more rapidly than either the metal wear tip 2 or the replaceable hard wear tip 28 of the present invention, described below. More significantly, the prior art leading outside diameter 17 , is smaller than either the prior art nozzle body shoulder 18 or the prior art wrench flat shoulder 19 of the nozzle body, making both surfaces 18 and 19 , reverse sand blasting targets. This exterior type, of a generally smaller diameter forward and larger diameter rearward is typical of existing nozzle assemblies, supersonic or otherwise. In most applications the nozzles are not supersonic nozzles, such as in cleaning applications or injection applications, and in such applications the nozzles do not encounter significant reverse sand blasting effects because they produce air jets of much smaller exit velocity and/or are not used for excavating purposes.
FIGS. 2A and 2B illustrate an example of another prior art failed supersonic soil excavating pneumatic nozzle construction. This nozzle assembly design has similar nozzle entrance 3 , nozzle throat 4 , and nozzle expansion exit 5 construction as found in the present invention as described below, however, the external construction of this prior art nozzle body results in premature failure in some soil excavation applications. The design of this nozzle assembly has an integral metal “wear tip” 2 formed of the same metallic material as the body of the nozzle. The metal wear tip 2 does not shadow the balance of the nozzle design, thus both the wear tip eroded material 21 and the nozzle eroded material 22 suffer significantly in a very short time (less than a month) sufficient to cause nozzle failure by erosion, at the erosion into nozzle interior 25 . Also, the wrench flats 8 are so far forward that they open a reverse sand blasting target.
FIG. 3A is a cross section of one embodiment of a supersonic air nozzle assembly according to one embodiment of the invention, which is a supersonic nozzle body 1 , with a removable wear tip 2 of metal, where the wear tip outside diameter 10 is generally larger that the outside diameter 9 of the nozzle body 1 , thus protecting the nozzle body 1 from reverse sand blasting. Also, the interior 27 of the forward wear tip 2 , is sloped or otherwise contoured to direct any nearby reverse sand blasting materials to be conveyed to the side of the exiting jet so as to protect the nozzle exit 5 from this effect. Also, each anterior transition such as 11 , 12 of the nozzle assembly exterior shape is sloped gently relative to the nozzle axis so as to avoid snagging of any of these surfaces on tree roots or other buried objects when the nozzle assembly is being extracted from the soil. FIG. 3B is an end view of FIG. 3A and illustrates it's generally round shape.
FIG. 4A is the cross section of an assembled alternative embodiment of the invention, that uses the very hard wear tip 2 material such as Cerbide™ material, etc. constructed as a removable wear tip, where the outside diameter of the wear tip 10 is equal to or somewhat larger in diameter than the diameter 9 of the nozzle body 1 . FIG. 4C is the same embodiment as FIG. 4A , but illustrates each of separate parts, before assembly.
FIGS. 3A and B, 4 A and B and 5 A and B illustrate three preferred embodiments of a supersonic nozzle assembly having a nozzle body 1 with a wear tip 2 that is used for excavating soil.
Typically, a supersonic nozzle assembly includes a nozzle body 1 which will have a nozzle entrance 3 , a constricting nozzle throat 4 operating at sonic flow, a nozzle expansion exit 5 that causes air flow to exit at supersonic speed. In FIG. 3A , the metal wear tip 2 is constructed of any one of several metals that are commonly used to construct nozzles (stainless steel, etc.). The metal wear tip outside diameter 10 is larger than the nozzle body outside diameter 9 , both of which are generally cylindrical. This provides a protective and sacrificial material to absorb the reverse sand blasting erosion that occurs when excavating in sandy soils or soils containing significant quantities of small, hard particles, typically the size of sand, that in time, will erode any exposed, forward facing nozzle surface.
This metal wear tip 2 , also has a generous metal wear tip extension 37 for the same purpose. If the metal wear tip outside diameter 10 were to be smaller that the nozzle body outside diameter 9 , the reverse sand blasting will immediately wear the outside of the wear tip 2 and, more or less simultaneously, the external shape of the nozzle body, as well, as in prior art structures. In surprisingly short time periods (weeks), this can lead to nozzle failure as the nozzle body is worn through to the interior. Conventional supersonic nozzle assemblies in use have leading exterior diameters 17 , see FIG. 1 , that are smaller in diameter than the trailing nozzle body outside diameter 9 , so in the many operating conditions, they wear out quickly.
A similar issue occurs near the nozzle expansion exit 5 . This invention places a forward, inclined or curved wear tip inside surface corner 26 sufficiently close to the nozzle expansion exit 5 , that any reflected hard particles entrained in reflected air in that region are directed closely towards the exiting air stream, so that those particles are inducted into exiting supersonic air stream and directed away from the nozzle. Also, the inside wear tip entrance corner 27 , is placed at an inclined radial location relative to the wear tip inside surface corner 26 , in a smoothly inclined relationship, so that reverse sand blasting particles in this region of the tip 2 are directed towards the wear tip inside surface corner 26 , thence inducted into that air stream and directed away from the nozzle assembly.
Similarly, any nozzle trailing external surface must be shadowed by the metal wear tip 2 , and ideally also by any leading nozzle exterior features. This requires that any wrench flats 8 must be near the rear of the nozzle exterior. Another requirement for the exterior nozzle body 1 and metal wear tip 2 surfaces is they must be connected to the next exterior shape in turn by a taper or other similar shape that has a shallow inclination to the central axis of the nozzle such as the wear tip reverse angle 11 , the wrench flat reverse angle 12 and the nozzle end reverse angle 13 so that when the nozzle assembly is being withdrawn from the soil, it will not snag on roots or other buried objects. There needs to be a nozzle to barrel connection 7 , so as to receive an air supply of suitable pressure and quantity of flow in a conventional fashion.
FIG. 4A is an assembled, optional embodiment of the nozzle assembly according to the present invention. It has the same or similar nozzle entrance 3 , nozzle throat 4 , and nozzle expansion exit 5 of FIG. 3A of a supersonic nozzle. It also has the external nozzle features of the nozzle in FIG. 3A , including the same nozzle outside diameter 9 , wrench flats 8 with a wrench flat reverse angle 12 , and nozzle end reverse angle 13 . The nozzle assembly employs a replaceable hard wear tip 28 , whose wear tip outside diameter 10 , is the same as or somewhat larger than the nozzle outside diameter 9 , and where the material of the replaceable hard wear tip 28 is any of a Cerbide™ material, any cemented carbide, or carbide(s), of boron, titanium, tungsten or other extremely hard and highly wear resistant material or combination.
Similar to the embodiment of FIG. 3 , this embodiment of FIG. 4A also places an inclined or curved wear tip inside surface corner 26 that is placed sufficiently close to the nozzle expansion exit 5 , that any reflected hard particles entrained in reflected air in that region are directed closely towards the exiting air stream, so that those particles are inducted into that air stream and directed away from the nozzle assembly. Also, the inside wear tip entrance corner 27 , is placed at an inclined radial location relative to the wear tip 28 inside surface corner 26 , in a smoothly inclined relationship, so that reverse sand blasting particles in this region are directed towards the wear tip inside surface corner 26 , thence inducted into the supersonic air stream exiting the nozzle assembly, and directed away from the nozzle assembly.
The hard material of the tip 28 resists conventional machining, shapes, such as the one shown, can be formed by hot pressing into a mold and by similar methods. Thus small threads are difficult to form. For this and other reasons of convenience, a metallic wear tip insert 29 , containing a threaded wear tip to nozzle connection 6 , is pressed into the molded, replaceable hard wear tip 28 , so it may be readily attached to a supersonic nozzle 1 , previously machined from metal.
FIG. 4C is an exploded view of the assembled optional preferred embodiment of FIG. 4A , for clarity and to indicate the assembly process, as follows. The machined wear tip insert 29 , is pressed into replaceable hard wear tip 28 , such that the wear tip insert press fit 31 (i.e. the outer diameter surface), has a small interference fit with the wear tip press fit 30 (i.e. the inner diameter surface). The two parts are pressed together until the wear tip alignment surface 32 , aligns against the wear tip insert alignment surface 33 .
FIG. 5A is an assembled, optional embodiment of the nozzle assembly of the invention. It has all of the features of FIG. 4A , except that it employs a replaceable hard wear tip 28 , whose wear tip outside diameter 10 , is smaller than the nozzle outside diameter 9 , and where the material of the replaceable hard wear tip 28 is any of a Cerbide™ material, any cemented carbide, or carbide(s), of boron, titanium, tungsten or other extremely hard and highly wear resistant material or combination. Further, this hard wear tip 28 has an inclined or other shaped leading edge 38 , that directs a reverse sand blasting first portion 34 , around the wear tip 28 , and into a reverse sand blasting second portion 35 , that would otherwise erode the “exposed” portion of the nozzle exterior, thus redirecting the combined flow 36 , away from the exterior of the nozzle body 1 .
In short the present invention provides a tool suitable for soil excavation that can be used in a number of distinct applications, wherein the tool includes a sonic or supersonic pneumatic nozzle body 1 with a wear tip 2 or 28 , preferably replaceable, each part constructed of a typical nozzle material such as stainless steel, brass, aluminum, etc., where the nozzle in combination with it's wear tip, are both generally uniformly cylindrical in exterior shape, and whose wear tip outside diameter(s) is larger than any external diameter of the nozzle body.
Although the present invention has been described with particularity herein, the scope of the present invention is not limited to the specific embodiment disclosed. It will be apparent to those of ordinary skill in the art that various modifications may be made to the present invention without departing from the spirit and scope thereof. The scope of the invention is not to be limited by the illustrative examples described above. The scope of the present invention is defined by the appended claims and equivalents thereto.
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A tool suitable for soil excavation that can be used in a number of distinct applications is disclosed, wherein the tool includes a sonic or supersonic pneumatic nozzle assembly comprising a converging-diverging cylindrical nozzle body having an internal through passage with inlet on the converging side and an outlet on the diverging side of the nozzle body; and a replaceable cylindrical wear tip removably coupled to the nozzle body and with an internal through passage aligning with the outlet of the nozzle body, and wherein an outside form of the wear tip is configured to direct reverse sand blasting particles away from the external surfaces of the nozzle body.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C §119(e) of U.S. Provisional Patent Application Ser. No. 60/690,174 filed Jun. 13, 2005, and U.S. Provisional Patent Application Ser. No. 60/759,805, filed Jan. 17, 2006, the contents of all of which are incorporated herein by reference for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING
[0003] Not Applicable
REFERENCE TO A TABLE
[0004] Not Applicable
REFERENCE TO A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0005] Not Applicable
BACKGROUND OF THE INVENTION
[0006] 1. Field Of The Invention
[0007] This disclosure relates generally to processes for the production of elemental sulfur from sulfur dioxide, and more particularly to processes for the recovery of sulfur from effluent streams containing sulfur dioxide.
[0008] 2. Description of the Related Art
[0009] Sulfur dioxide is found in many industrial gases emanating from plants involved in roasting, smelting and sintering sulfide ores, or gases from power plants burning high sulfur coal or fuel oils or other sulfurous ores or other industrial operations involved in the combustion of sulfur-bearing fuels, such as fuel oil. One of the more difficult environmental problems facing industry is how to economically control SO 2 emissions from these sources.
[0010] Several processes schemes have been developed to recover elemental sulfur from SO 2 streams. There are several fundamental problems common to these efforts. In particular, byproduct formation of H 2 S, CS 2 , COS, H 2 and CO reduces sulfur recovery and fuel efficiency and requires larger equipment because of the increased gas flow. Soot formation reduces the quality of the sulfur product and fouls the equipment and catalyst beds reducing the reliability of the unit.
[0011] The thermal reduction of SO 2 to Sulfur was developed during 1909-11, S. W. Young investigated reduction of SO 2 with methane and other hydrocarbons on a laboratory scale, (Fleming, E. P., and Fitt, T. C., High Purity Sulfur from Smelter Gases—Reduction with Natural Gas, Ind. Eng. Chem., 42, 2249-2253, November 1950). In a 1934 article, Yushkevich, and others discuss in detail the various possible reaction products from the combination of SO 2 and a hydrocarbon reducing agent, including H 2 S, COS, CS 2 and sulfur. Experiments suggested 900-1000° C. as the optimum temperature. (Yushkevich, et al., ZH. KHIM. PROM., No. 2, pp. 33-37, 1934; U.S. Pat. No. 3,928,547, entitled “Process for the Reduction of Sulfur Dioxide”, Daley, W. D., Wilkalis, J. E., and Pieters, W. J. M., assigned to Allied Chemical Corp., Dec. 23, 1975). In 1938, the American Smelting and Refining Company (ASARCO) initiated investigations in this area, which soon indicated that relatively low-grade SO 2 might be directly converted to reasonably pure sulfur by reduction with natural gas. (Fleming, E. P., and Fitt, T. C., High Purity Sulfur from Smelter Gases—Reduction with Natural Gas, Ind. Eng. Chem., 42, 2249-2253, November 1950). Laboratory and small-scale pilot operations were gradually expanded until a semi-commercial 5-tpd unit was operated during 1940-45. Gas from copper roasters or converters containing 5-8% SO 2 and 9-12% oxygen was combusted with sufficient natural gas to consume all the oxygen to CO 2 , plus additional fuel to react with an appropriate portion of the SO 2 according to the following overall reaction with CH 4 as shown in the following reaction:
2SO 2 +CH 4 →2H 2 O+CO 2 +S 2
[0012] Considerable quantities of byproduct H 2 S, COS and CS 2 were formed as well. Furnace temperatures of at least 1250° C. were considered necessary to minimize soot, which will discolor the sulfur. The gases were then cooled and passed through a series of Claus stages for hydrolysis of COS and CS 2 to H 2 S and reaction of residual H 2 S and SO 2 to sulfur according to the Claus reaction. This process is still employed today where potential sulfuric acid supply exceeds demand. In 1978, Davy Power gas GmbH proposed a staged combustion process where hydrocarbon gas is burned at near stoichiometric conditions, followed by injection of supplemental CH 4 and SO 2 which react to form elemental sulfur. (U.S. Pat. No. 4,117,100, Hellmer, L., Koller, G., Muddarris, G. R. A., and Sud, K. K., Process for Reduction of Sulfur Dioxide to Sulfur, Davy Powergas GmbH, Sep. 26, 1978). It is also claimed that the presence of water vapor in the SO 2 feed stream suppresses soot formation. The process was never commercialized.
[0013] Catalytic Reduction of SO 2 to Sulfur was considered in a 1934, when United Verde Copper Company proposed a process where a portion of the SO 2 stream is combined with CH 4 at 800-850° C. in the presence of a metal sulphide catalyst to produce H 2 S, which is subsequently reacted with the remaining SO 2 to yield sulfur according to the Claus reaction. (U.S. Pat. No. 1,967,263, Rosenstein, L., entitled “Recovery of Sulfur”, United Verde Copper Company, Jul. 24, 1934). The Claus stage was described to comprise a bed of granular absorbent, such as bauxite or charcoal, continually wetted by a thin film of liquid water which served to absorb the reaction heat and also carry away the product sulfur for subsequent recovery by filtration or sedimentation. The process was never commercialized. In 1965, Texas Gulf Sulfur patented the reduction of SO 2 with hydrocarbons (e.g.: CH 4 ) at 750-1000° C. using a catalyst such as alumina, initially achieving 40-60% sulfuir recovery (U.S. Pat. No. 3,199,955, West, J. R., and Conroy, E. H., entitled “Process of Reducing Sulfur Dioxide to Elemental Sulfur”, Aug. 10, 1965). Two similar catalytic stages typically followed, whereby the second stage achieved at 390° C., with the sequence of hydrolysis of byproduct COS and CS 2 to H 2 S, Claus reaction of H 2 S and SO 2 to form sulfur and reduction of SO 2 by CO and H 2 to sulfur. Claus reaction of residual H 2 S and SO 2 further proceeded in the third stage for 95% overall sulfur recovery. No method of controlling the heat release from the reduction reactions is described and the process was never commercialized.
[0014] In 1975, Allied Chemical Corp. claimed to have discovered that, at SO 2 concentrations on the order of 50% and higher, a small amount of elemental sulfur (0.1-3 mol-% of the feed gas as S 8 ) lowered the initiation temperature for SO 2 reduction and favorably moderated the temperature rise and rate. The sulfur also expedited the reaction and minimized byproduct H 2 , CO, COS and CS 2 formation, (U.S. Pat. No. 3,928,547, entitled “Process for the Reduction of Sulfur Dioxide”, Daley, W. D., Wilkalis, J. E., and Pieters, W. J. M., assigned to Allied Chemical Corp., Dec. 23, 1975). Generation of H 2 and CO is particularly counterproductive because it decreases sulfur recovery and fuel efficiency and requires larger equipment because of the increased tail gas volume. In 1977, Allied Chemical presented a 3-bed arrangement that was claimed to optimize reactant concentrations and temperatures, (U.S. Pat. No. 4,039,650, Daley, W. D., entitled “Sulfur Dioxide Reduction”, Allied Chemical Corp., Aug. 2, 1977). The total SO 2 stream is reported to be mixed with a portion of the CH 4 and passed through the first reactor to effect reduction of a portion of the SO 2 to H 2 S and sulfur. Exit gas from the first reactor is mixed with the remaining CH 4 , and the resultant mixture split into two gas streams which are then passed, in parallel, through a second and third reactor to further effect reduction of SO 2 to H 2 S and sulfur. Periodically, the flow in the first and third reactors is reversed to subject them to alternating heat absorbing and desorbing cycles (while the second reactor is always maintained in the same direction). Inlet gas temperatures to the second and third reactors are maintained within desired ranges by bypassing a portion of the SO 2 and CH 4 around the first reactor. A 25-tpd pilot plant was constructed in 1978 at a 115-MW coal-fired power plant.
[0015] The catalytic reduction of sulfur to intermediate H 2 S was also considered. Early research on the recovery of sulfur from gypsum (CaSO 4 .2H 2 O) involved reduction roasting of gypsum with coal or natural gas to form calcium sulfide, which was subsequently processed to generate H 2 S. In the laboratory, elemental sulfur was then produced by reacting H 2 S with SO 2 at ambient temperature in a liquid medium. That latter concept led the Federal Bureau of Mines, beginning in 1968, to consider absorption of SO 2 (from nonferrous smelters) in a liquid medium subsequently regenerated with H 2 S to precipitate sulfur. After screening many reagents, an aqueous solution of citric acid neutralized with soda ash to a pH of 4.5 was selected, (Crocker, L., Martin, D. A., and Nissen, W. I., “Citrate-Process Pilot-Plant Operation at the Bunker Hill Company”, Bureau of Mines Report of Investigations 8374, p. 1-6, 1979). At least three pilot plants were operated during 1971-76. The most recent was located at the Bunker Hill Co.'s lead smelter in Kellogg, Id. In the absence of an external source, H 2 S was generated by the reaction of natural gas with sulfur vapor at 650° C. over a proprietary catalyst as shown in the following reaction:
CH 4 +4S→CS 2 +2H 2 S
[0016] The product CS 2 was subsequently hydrolyzed with steam in a second catalytic stage at 315° C. as shown in the following reaction:
2H 2 S+CS 2 +2H 2 O→4H 2 S+CO 2
[0017] The so-called “Citrate Process” for the Claus reaction of H 2 S and SO 2 within a liquid absorbent was ultimately abandoned due to absorber corrosion and plugging problems. (Kohl, A. L., and Nielsen, R. B., Gas Purification, Fifth Edition, p. 564, Gulf Publishing Co., 1997).
[0018] During 1978-1980, a series of three U.S. patents by D. K. Beavon, as described below, proposed innovations to reduce equipment costs and improve operability and product quality. A common theme was the efficient reduction of recycled sulfur to H 2 S for subsequent reaction with SO 2 to produce sulfur, while minimizing the soot formation characteristic of direct SO 2 reduction. Sulfur reduction by submerged hydrocarbon combustion was described in a 1978 patent, wherein H 2 and CO are initially formed in a reducing gas generator by the partial combustion of a hydrocarbon fuel, with steam injection to suppress soot formation. The fuel can be gaseous (such as methane), liquid (such as kerosene, diesel or other fuel oil) or solid (such as coal or coke), (U.S. Pat. No. 4,094,961, Beavon, D. K., entitled “Hydrogen Sulfide Production”, Ralph M. Parsons Company, Jun. 13, 1978).
[0019] The reducing gas is reportedly then sparged through molten sulfur, so that combustion temperatures are rapidly quenched by sulfur vaporization. The firing rate is adjusted to produce a 250-450° C. vapor stream with a nominal stoichiometric excess of hydrogen, which is then passed across a fixed cobalt-moly catalyst bed. Elemental sulfur is hydrogenated to H 2 S. Byproduct COS and CS 2 are hydrolyzed to H 2 S, and CO is hydrolyzed to CO 2 and H 2 . Sufficient reaction heat is generated that multiple beds with inter-stage cooling are typically required. Reactor effluent is cooled in the sulfur cooler to condense any residual sulfur vapor, particularly during non-routine operation, while remaining above the water dew point. The gas is then further cooled to condense most of the water vapor, yielding an H 2 S-rich stream that can then be reacted with SO 2 in a conventional Claus reactor to produce elemental sulfur. The process has not been commercialized. The reduction of sulfur in a reaction furnace was described in a 1979 patent, wherein hydrogen and CO are similarly generated by partial oxidation of a hydrocarbon, gaseous or liquid, in the first zone of a 2-zone furnace, and a stoichiometric excess of liquid sulfur is injected into the second zone to quench temperatures to 800-1100° C., (U.S. Pat. No. 4,146,580, Beavon, D. K., entitled “Process for Hydrogen Sulfide Production”, Ralph M. Parsons Company, Mar. 27, 1979).
[0020] A portion of the H 2 and CO react with the sulfur to form H 2 S, COS and some CS 2 , with about 50% of the total H 2 S production being achieved in the furnace. The resultant vapor stream is rapidly cooled to 425° C. or less in a waste heat boiler to suppress further formation of undesirable organic sulfur byproducts. The stream is then further cooled to condense and remove most of the residual sulfur. The gas stream is then typically reheated for conventional catalytic hydrogenation of sulfur and SO 2 to H 2 S, hydrolysis of COS and CS 2 to H 2 S and hydrolysis of CO to CO 2 and hydrogen. The reactor effluent is then cooled by conventional means to ultimately condense most of the water vapor, yielding an H 2 S-rich gas stream that can be subsequently reacted with SO 2 in a conventional Claus reactor to yield elemental sulfur. As with the previous process, this process has not been commercialized.
[0021] The thermal reduction of SO 2 was developed in a 1980 patent, wherein a hydrocarbon fuel, gaseous or liquid, is partially oxidized in a reaction furnace to generate H 2 and CO. Sulfur dioxide (SO 2 ) added to the thermal reaction zone to react with the H 2 and indirectly, CO (by virtue of water gas shift to CO 2 and H 2 ). The firing rate was adjusted to yield a mixture of H 2 S and SO 2 in the molar ratio of 2:1 as required by Claus stoichiometry (U.S. Pat. No. 4,207,304, Beavon, D. K., entitled “Process for Sulfur Production”, Ralph M. Parsons Company, Jun. 10, 1980).
[0022] Competing reactions in this process are the formation of COS and CS 2 from the reaction of CO and free carbon with SO 2 and sulfur. Potential soot may be washed from the system by the introduction of liquid sulfur, which is recycled to enable consumption of extracted carbon. The resultant vapor stream is rapidly cooled to 425° C. or less to suppress further formation of undesirable organic sulfur byproducts. Elemental sulfur can be recovered and recycled to the reactor for gasification of extracted carbon solids and tars.
[0023] Further sulfur recovery is achieved as the process gas proceeds through a series of conventional catalytic Claus stages.
[0024] This application for patent discloses processes for the production of elemental sulfur from sulfur dioxide.
BRIEF SUMMARY OF THE INVENTION
[0025] The present invention relates to a process for recovering sulfur from sulfur dioxide (SO 2 ) containing gases. Key advantages are lower fuel consumption, reduced emissions, better product sulfur quality and better operational stability.
[0026] In accordance with aspects of the present invention, a reducing gas, for example a hydrocarbon such as methane, methanol, or a H 2 and CO mixture, is contacted with elemental sulfur to produce a reducing gas that contains hydrogen sulfide. The H 2 S containing reducing gas is then contacted with a stream that contains SO 2 to produce elemental sulfur, a portion of which may be recycled back to the fist step of the process.
[0027] In accordance with further aspects of the present invention, processes for the production of sulfur from sulfur dioxide (SO2)-containing effluent streams are described, wherein the processes comprise contacting a reducing agent with elemental sulfur at a first elevated temperature in a heater for a period of time sufficient to produce a reducing gas effluent stream comprising hydrogen sulfide; contacting the reducing gas with a sulfur dioxide-containing stream to generate a feed gas mixture stream; contacting the feed gas mixture stream with an activated catalyst in a reaction zone at a temperature effective for the reaction between hydrogen sulfide and sulfur dioxide to generate a product gas stream comprising elemental sulfur and water; and, recovering the elemental sulfur from the product gas stream.
[0028] In accordance with another aspect of the present invention, a process for converting sulfur dioxide is described, wherein the process comprises introducing a reducing agent into a heater; introducing elemental sulfur into a heater; contacting the reducing agent and the elemental sulfur in a first reactor at a temperature ranging from about 600° C. to about 1000° C. for a period of time sufficient to form a reducing gas effluent stream comprising H 2 S, COS, or CS 2 ; contacting the reducing gas with a sulfur dioxide-containing effluent stream in a second reactor at an elevated temperature for a time sufficient to form a product gas stream comprising elemental sulfur; and, cooling the product gas stream in one or more sulfur condensers to condense and recover elemental sulfur.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The following figures are part of the present disclosure and are included to further illustrate certain aspects of the present invention. Aspects of the invention may be understood by reference to one or more figures in combination with the detailed written description of specific embodiments presented herein.
[0030] FIG. 1 illustrates a schematic diagram of an embodiment of the present invention;
[0031] FIG. 2 illustrates a schematic diagram of an alternate embodiment of the present invention in which a CS 2 product is produced;
[0032] FIG. 3 illustrates a schematic diagram of an alternate embodiment of the present invention in which steam is injected.
[0033] While the inventions disclosed herein are susceptible to various modifications and alternative forms, only a few specific embodiments have been shown by way of example in the drawings and are described in detail below. The figures and detailed descriptions of these specific embodiments are not intended to limit the breadth or the scope of the inventive concepts or the appended claims in any manner. Rather, the figures and detailed written descriptions are provided to illustrate the inventive concepts to a person of ordinary skill in the art and enable such person to make and use the inventive concepts.
DETAILED DESCRIPTION OF THE INVENTION
[0034] One or more illustrative embodiments incorporating the invention disclosed herein are presented below. Not all features of an actual implementation are described or shown in this application for the sake of clarity. It is understood that in the development of an actual embodiment incorporating the present invention, numerous implementation-specific decisions must be made to achieve the developer's goals, such as compliance with system-related, business-related, government-related and other constraints, which vary by implementation and from time to time. While a developer's efforts might be complex and time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill the art having benefit of this disclosure.
[0035] In general terms, Applicant has created new processes converting sulfur-dioxide and sulfur-dioxide-containing effluents into elemental sulfur.
[0036] In the discussion of the Figures, the same or similar numbers will be used throughout to refer to the same or similar components. Not all valves and the like necessary for the performance of the process have been shown in the interest of conciseness.
[0037] In FIG. 1 , a reducing agent ( 49 ) comprising a hydrocarbon, methanol, a hydrogen and carbon monoxide mixture, or mixtures thereof, and liquid sulfur ( 51 ) are separately preheated to a temperature from about 500° C. (932° F.) to about 650° C. (1200° F.), at a pressure of about 72 psig (about 500 kPag), in an H 2 S generator ( 1 ). If a hydrocarbon is employed as reducing agent ( 49 ), or as a part of a reducing agent mixture, the hydrocarbon reducing agent may be selected from the group consisting of alkanes, alkenes, alkynes, cycloalkanes, aromatic hydrocarbons, and mixtures thereof.
[0038] In reference to reducing agent ( 49 ), and as used herein, the term hydrocarbon is meant to refer to those organic compounds (both saturated and unsaturated) composed solely of the elements hydrogen and carbon. Suitable hydrocarbon reducing agents for use herein include but are not limited to alkanes of the general formula C n H 2n+2 (wherein ‘n’ is an integer greater than or equal to 1), such as methane, ethane, propane, n-octane, and the like, as well as mixtures of alkanes; alkenes of the general formula C n H 2n (wherein ‘n’ is an integer greater than or equal to 1), including 1-butene and 1-propene, and mixtures of alkenes; alkynes of the general formula C n H 2n−2 (wherein ‘n’ is an integer greater than or equal to 1), and mixtures of alkynes; cycloalkanes of the general formula C n H 2n (wherein ‘n’ is an integer greater than or equal to 1), including cyclohexane and other “naphthenes”, as well as mixtures thereof; aromatic compounds of the general formula C n H 2n−6 , including both monocyclic (benzene) and polycyclic (napthene) aromatics; as well as mixtures of the above described hydrocarbons. Suitable reducing agents can also be formed by the combustion of a hydrocarbon in the presence of an amount of oxygen insufficient for the complete oxidation of the hydrocarbon.
[0039] The H 2 S reactor ( 1 ) may be any suitable heater, externally-fired heater, furnace, reactor or generator, such as those externally fired systems commonly used in ethylene cracking operations or CS 2 production. Fuel ( 50 ) may be combusted in the H 2 S generator to provide heat. Fuel ( 50 ) may be any suitable fuel, including, but not limited to, gaseous fuels (such as methane or propane), liquid fuels (such as kerosene, diesel, or other fuel oil), solid fuels (such as coal or coke), or combinations thereof. In a preferred embodiment of the reactor, heat transfer to the transfer coils occurs primarily by radiation with little or no direct contact of the flame. The reducing agent and sulfur react at a temperature in the range of about 600° C. (1110° F.) to about 1832° C. (3300° F.). The tubes are typically constructed of a high nickel-chrome alloy.
[0040] The liquid sulfur boils at about 445° C. (833° F.), and vaporizes at about 450° C. (840° F.), at which temperature it exists mainly as orthorhombic sulfur (S 8 ). Subsequent superheating to a temperature ranging from about 500° C. to about 650° C. (about 930° F. to about 1200° F.) results in endothermic decomposition to smaller, more reactive, species (e.g., S 6 and S 2 ). This dissociation is also favored by the reduction in partial pressure of the sulfur vapor as H 2 S and CS 2 are formed in the reactor. Consequently, it is desirable to preheat the vapor to the maximum reaction temperature before combination with the reducing agent, to minimize the reactor temperature drop resulting from the endothermic dissociation of the sulfur. The reducing agent and sulfur vapor are then contacted and mixed. The amount of reducing agent fed to the unit may be controlled to maintain the mole ratio of H 2 S to SO 2 in the tail gas stream ( 67 ). It is presently preferred that the H 2 S to SO 2 mole ratio be controlled so as to be in a range from about 2:1 and about 5:1.
[0041] The combined stream flows through a radiantly heated pipe coil, where the reaction between the reducing agent and sulfur proceeds. The primary reactions that may occur are:
CH 4 +2S 2 →CS 2 +2H 2 S
2CH 3 OH+2S 2 →2COS+2H 2 S
2H 2 +S 2 →2H 2 S
2CO+S 2 →2COS
[0042] The reactions between the reducing agent and the sulfur may be further completed in one or more H 2 S generator reactors ( 2 , 3 , 4 ) that contain fixed catalyst beds. The catalyst may be any of the catalysts commonly used in CS 2 production plants, for example, activated alumina (Al 2 O 3 ) or silica gel.
[0043] In accordance with aspects of the present invention, the catalysts suitable for use with the processes described herein comprise those containing one or more metals or combinations of metals of Group 4, Group 5, Group 6, Group 8, Group 9, Group 10, Group 14, Group 15 and the Rare Earth series (Group 3 elements and the lanthanides) of the Periodic Table, as described and referenced in “Advanced Inorganic Chemistry, 6 th Ed.” by F. A. Cotton, et al. [Wiley-Interscience, (1999)], any of which can be present on a suitable, conventional inorganic support material. The preferred catalysts for use with the processes described herein include, but are not limited to, those containing one or more of the metals selected from the group consisting of cobalt, titanium, iron, chromium, vanadium, nickel, tungsten, germanium, zinc, cerium, and antimony, as well as combinations of two or more of these metals, such as in cobalt-molybdate catalysts. In accordance with one aspect of the present invention, the catalyst comprises titanium. In the event that the catalyst used in the processes of the present disclosure is a mixture of two metals, the ratio (on an atomic basis) of these metals is preferably between about 10:90 and 97.5:2.5, and more particularly ranges from about 25:75 to about 95:5, including ratios between these values, such as about 50:50.
[0044] Suitable supports for use in accordance with the catalysts and catalyst systems useful with the present inventions include ceramic materials, sintered metals, oxides, activated alumina or alumina-based materials, and silica gel, as well as mixtures thereof, such as alumina mixed with one or more other oxides. Suitable oxides include silica, titanium oxide, zirconium oxide, cerium oxide, tin oxide, trivalent rare-earth oxides, molybdenum oxide, cobalt oxide, nickel oxide, iron oxide, and the like. Activated alumina or alumina-based materials suitable for use herein include but are not limited to hydrated alumina compounds such as hydrargillite, bayerite, boehmite, pseudoboehmite, and amorphous or substantially amorphous alumina gels. Exemplary alumina and alumina-based materials can include aluminas which contain at least one of the phases taken from the group consisting of alpha, beta, delta, theta, kappa, gamma, eta, chi, rho, and mixtures thereof, as well as aluminas obtained by methods such as precipitation, rapid dehydration of aluminum hydroxides or oxyhydroxides, and/or calcining processes, as well as by other methods known to those of skill in the art. As indicated above, and in accordance with an aspect of the present invention, the catalysts for use with the processes of the present disclosure are those commonly used in CS 2 production plants, for example, activated alumina (Al 2 O 3 ) or silica gel.
[0045] The reaction between the sulfur and reducing agent continues in the reactors. After the first reactor, the gas may be reheated in the H 2 S generator heater before entering the subsequent reactors, if any. Excess sulfur may be fed to the H 2 S generator to maximize conversion of the reducing agent and to minimize side reactions. It is presently preferred that the excess sulfur be fed at a rate at least 5% to 10% above the rate required for completion of the reactions.
[0046] The effluent gas ( 52 ) from the final H 2 S generator reactor may be cooled to condense sulfur. FIG. 1 depicts a two stage system in which the gas is cooled to about 340° C. ( 53 ) in a waste heat boiler ( 7 ) that generates high pressure 600 psig (4200 kPag) steam, then subsequently the gas ( 53 ) cools in the No. 1 Sulfur condenser ( 8 ) to about 150° C. (300° F.) by the generation of low-pressure (50 psig; 350 kPag) steam to condense most of the residual sulfur vapor, which then drains to the collection pit ( 22 ) through one or more drain lines ( 80 ). The number of coolers and cooling medium may be adjusted without affecting the process. The cooled gas stream ( 54 ) may then be reheated to about 210° C. (410° F.) in a No. 1 Reheater ( 9 ).
[0047] With continued reference to FIG. 1 , a sulfur dioxide (SO 2 ) stream ( 56 ) with a molar concentration of SO 2 ranging from about 1% to about 100% is then introduced to the unit. The sulfur dioxide stream can come from any number of suitable SO 2 sources, including but not limited to tail gas streams from any number of process plants, the condensation of enriched stripper gases, tail gas effluent, and the like; from the combustion of fossil fuels; from the burning of crude oils; from the smelting of sulfide ores such as iron pyrites and sphalerite (zinc blende); and heating calcium sulfate (gypsum) with coke and sand in the manufacture of cement. In accordance with an aspect of the present invention, the SO 2 stream is preferably pretreated to remove particulate material and concentrate the stream to a molar concentration ranging from about 25% to about 100% before entering the unit, although removal of particulates and concentration is not necessary for operation of the presently described process. The SO 2 stream is heated in an SO 2 preheater ( 6 ) and the heated SO 2 stream ( 57 ) is combined with the heated H 2 S stream ( 58 ). The combined stream ( 59 ) enters reactor No. 1 sulfur reactor ( 10 ) containing a fixed bed of activated catalyst, preferably an alumina or titania catalyst of the type normally employed in Claus sulfur recovery units. In the reactor, H 2 S and SO 2 react to form elemental sulfur according the following reaction:
2H 2 S+SO 2 →3/X S X +2H 2 O
[0048] Carbonyl sulfide (COS) and carbon disulfide (CS 2 ) may be concurrently hydrolyzed in the reactor to form hydrogen sulfide (H 2 S) according the following reactions:
COS+H 2 O→H 2 S+CO 2
CS 2 +2H 2 O→2H 2 S+CO 2
[0049] FIG. 1 illustrates a two stage system in which the effluent gas stream ( 60 ) from the No. 1 Sulfur reactor ( 10 ) is cooled to about 340° C. (650° F.) in the SRU (Sulfur Recovery Unit) waste heat boiler ( 11 ) by the generation of high-pressure steam, then subsequently to about 150° C. (300° F.) by the generation of low-pressure steam in the No. 2 sulfur condenser ( 12 ) to condense most of the residual sulfur vapor, which drains to the collection header stream ( 81 ). The number of coolers and cooling medium may be adjusted without affecting the process.
[0050] When processing a concentrated SO 2 stream, a portion of the process gas stream ( 61 ) may be recycled to the No. 1 SRU reactor, via a low-head centrifugal recycle blower ( 13 ). The effluent from the blower ( 68 ) may be heated in the reheater recycle gas preheater ( 14 ) and the reheated stream ( 69 ) mixed with the reactor feed to dilute the reactants as necessary to limit the exothermic temperature rise.
[0051] Ultimately, the process gas stream ( 61 ) may be sent to one or more the additional reaction stages in order to increase sulfur recovery efficiency. For example, FIG. 1 illustrates a second reaction stage, comprising the No. 2 reheater ( 16 ), No. 2 sulfur reactor ( 17 ) and No. 3 sulfur condenser ( 18 ) for further reaction of residual H 2 S and SO 2 through streams ( 62 and 63 ), and liquid sulfur stream ( 82 ).
[0052] As with the first reaction stage, an alumina or titania catalyst may be used in the reactor. The reactants are sufficiently dilute at this point that tail gas recycle may not be required for temperature control, and the second and third stage reactors, if provided, may thus be considerably smaller. Similarly, FIG. 1 depicts a third reaction stage, comprising the No. 3 steam reheater ( 19 ), No. 3 sulfur reactor ( 20 ) and No. 4 sulfur condenser,( 21 ) for further reaction of residual H 2 S and SO 2 through streams ( 64 , 65 , and 66 ), and liquid sulfur stream ( 83 ) to the sulfur pit. The process is able to achieve an overall sulfur recovery efficiency of greater than 95% based on the theoretical amount of recoverable sulfur. For example, the sulfur recovery efficiency may be about 98% with a concentrated SO 2 feed stream and three reaction stages. The tail gas stream ( 67 ) may be incinerated and discharged to atmosphere or treated in any of the tail gas treating units used to treat Claus sulfur recovery unit tail gases to achieve nearly 100% sulfur recovery efficiency.
[0053] The liquid sulfur is colleted in a sulfur pit ( 22 ) or other collection device and may be handled by others, or shipped as appropriate.
[0054] In FIG. 2 , an alternate embodiment of the present invention is illustrated. In this embodiment, a CS 2 product ( 70 ) is separated from the H 2 S generator effluent stream ( 54 ). The separation of CS 2 may be by any of the methods typically used in CS 2 production plants.
[0055] In FIG. 3 , an alternate embodiment of the invention is illustrated. In this embodiment, steam ( 71 ) is injected before the final H 2 S generator reactor. The steam acts to hydrolyze some or all of the COS or CS 2 produced in the H 2 S generator.
[0056] All of the compositions, methods, processes and/or apparatus 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, methods, processes and/or apparatus and in the steps or sequence of steps of the methods described herein without departing from the concept and scope of the invention. Additionally, it will be apparent that certain agents which are both chemically and functionally related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes or modifications apparent to those skilled in the art are deemed to be within the scope and concept of the invention. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicant, but rather, in conformity with the patent laws, Applicants intends to protect all such modifications and improvements to the full extent that such falls within the scope or range of equivalents of the following claims.
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The reduction of gas streams containing sulfur dioxide to elemental sulfur is carried out by contacting a reducing gas, such as natural gas, methanol or a mixture of hydrogen and carbon monoxide, with recycled sulfur to produce a stream containing hydrogen sulfide that may be reacted with the gas stream that contains sulfur dioxide. Gas streams with a molar concentration of sulfur dioxide from 1 to 100% may be processed to achieve nearly 100% sulfur recovery efficiency.
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[0001] This application is a continuation of U.S. application Ser. No. 09/552,253, filed on Apr. 18, 2000, now U.S. Pat. No. 6,254,355, issued on Jul. 3, 2001, which claims the benefit of provisional U.S. application Ser. No. 60/130,408, filed Apr. 19, 1999, both of which are incorporated herein by reference.
BACKGROUND
[0002] Many different pump systems are known. A typical pump uses an impeller, which spins to push a flow of fluid in a direction. Less conventional pump designs are also known, and are used in places where the fluid can actually be damaged. For example, the pumping of red blood cells may require special considerations, e.g., care to avoid damaging the red blood cells.
SUMMARY
[0003] The present application uses the concept of hydro elastic operations to form a pump.
[0004] First and second elastic chambers are used to deliver a pumping action using a pressure head difference. The pumping action occurs in either forward or backward directions depending on the way in which the element is actuated.
[0005] This pump may operate without valves. It can operate in either an open or closed loop flow system. The system describes valveless and bladeless pumping of fluids in either steady or pulsatile mode. The application also describes applications of this pump, including operation for blood pumping, a specific operation for assisting the heart in series or parallel arrangements, such as a left ventricle assist device (LVAD) or as in-phase or counter pulsating device and any other medical application such as a venous pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other aspects will now be described in detail with respect to the accompanying drawings, wherein:
[0007] [0007]FIG. 1 shows the basic pump;
[0008] [0008]FIG. 2 shows a block diagram of the pump system in operation;
[0009] [0009]FIG. 3 shows an alternative mode;
[0010] [0010]FIG. 4 shows a pinching device; and
[0011] [0011]FIG. 5 shows an alternative volume reduction embodiment.
DETAILED DESCRIPTION
[0012] The basic pump is shown in FIG. 1. An elastic tube 100 is shown in unbroken lines. The elastic tube has a length L from end to end. This tube can be connected at each of its two ends 102 and 104 to tubes such as 106 . The tubes 106 can be of any type or shape.
[0013] The elastic tube 100 is divided into three segments, labeled A, P and B. Segment P is situated between segments A and B. FIG. 1 shows Segment P situated to provide an asymmetric fluidic characteristic. In FIG. 1, the asymmetric characteristic is geometric arrangement. As shown, the length of A is not equal to the length of B. Alternatively, the length of A can be equal to the length of B, but the elasticity or diameter of the two segments may be different from one another. This is done, to allow the pumping action to materialize.
[0014] Segment P 120 provides a means of compressing the diameter of segment P to reduce its volume. The pinching can be a partial obstruction or a complete obstruction. FIG. 1 shows the compression being partial; distorting the tube to the area shown as dashed lines 110 . In this respect, segment P can be a separately attached element configured in a “T” shaped piston/cylinder arrangement 500 , attached to the tube 100 , such as shown in FIG. 5.
[0015] When segment P is compressed, the volume within segment P is displaced to the segments A and B. This causes a rapid expansion of the volumes in A and B as shown by the line 110 . Similarly, for the “T” shaped piston/cylinder arrangement, the stroke of the piston displaces the volume in section P to sections A and B.
[0016] Since the segment B is shorter than segment A, the volume expansion in segment B is more than the volume expansion in segment A. Since the same volume has been added to segments A and B, the cross-sectional radius (R a ) of segment A will be larger than the corresponding radius (R b ) for segment B. The pressure inside each of these elastic containers varies with the inverse of the cross-sectional radius of the curvature of the elastic tubes, by virtue of the Laplace-Young law of elasticity,
P =2σ/ R
[0017] here P is the pressure, σ is the surface stress and R is the cross-sectional radius of curvature.
[0018] Therefore, liquid inside segment B will actually experience more pressure from the contracting force of the elastic tube wall. While this effect is counterintuitive, it is often experienced when blowing up a balloon. The beginning portions of blowing up the balloon are much more difficult than the ending portions. The same effect occurs in the asymmetric tube. The pressure in segment B will actually be larger than the pressure in segment A.
[0019] If the constriction of segment P is removed rapidly, before the pressures in segment A and B equalize with the total system pressure, then the liquid in the high pressure section B will flow toward the low pressure segment A. Hence, liquid flows from segment B towards segment A in order to equalize pressure. This creates a pumping effect.
[0020] The above has described the timing and frequency of the pinching process. This timing and frequency can be adjusted to control the volume flux as well as the direction of the flow. In addition, the size of the displaced volume depends on the relative size of segment P to the size of segments A and B. The ratios of P to A as well as the timing and frequency of the pinching may be used set various characteristics of the pump. For example, a 5 cm long tube of 1 cm in diameter can be divided to segments A=1 cm, P=1 cm and B=3 cb. At a frequency of 2 Hz and duty cycle of %20 (close to open ratio), this tube can pump up to 1.8 lit/min.
[0021] [0021]FIG. 2 shows the pump with a circuit and feedback system. In this embodiment, the pump tube 100 has less elasticity than the remainder of the system. The pipes 200 , as described herein, can be the pipes through which the fluid is flowing, such as body cavity, e.g. the aorta.
[0022] The feedback system includes a flow and pressure sensor 205 . The pinching element 210 is driven by a programmable driver 220 which also provides an output indicative of at least one of frequency, phase and amplitude of the driving. The values are provided to a processing element 230 , which controls the timing and/or amplitude of the pinching via feedback. The relationship between timing, frequency and displacement volume for the compression cycle can be used to deliver the required performance. The parameters A, B and P; as well as the tube diameter, its elasticity and its relative elasticity, that is, relative to the elasticity of the pipes into which fluid is being pumped, can all be controlled for the desired effect. These effects can be determined by trial and error, for example. For the clinical applications, one can use the given patient's variables and find the pump parameters that are based on the patient's information.
[0023] [0023]FIG. 2 shows the actuating system for the compressing process being based on a linear translation system that sandwiches the segment P. Other translation systems—including pneumatic, hydraulic, magnetic solenoid, or an electrical stepper or DC motor can also be used. The pseudo electrical effect could be used. The effect of contractility of skeletal muscles based on polymers or magnetic fluids, or grown heart muscle tissue can also be used. The system may use a dynamic sandwiching of the segments. However, it is also possible to use a coil only around the segment as shown in FIG. 3.
[0024] [0024]FIG. 4 shows a system where a magnet 400 has a substantially U-shaped yoke that provides a magnetic force that pulls the pincher element 405 on bearings 410 . This system can be advantageous, for many reasons. The bearings 410 can be formed in a simple and reliable way, since they only require back and forth motion. They can be spring-biased. Alternatively, they can operate without spring bias. In addition, if the plunger element 405 is nonmagnetic, then the magnetic force is between the end of yoke 415 and its attractive element 420 . When this happens, no magnetic force is provided through the tube 100 .
[0025] A number of different alternatives are also contemplated and are described herein. In addition, a number of improvements are expected. This system can be used for pumping blood. In contrast with existing blood flow systems, such as those used in traditional left ventricle devices, this system does not require any valve at all, and certainly not the complicated one-way valve systems which are necessary in existing devices. This can provide a more reliable device, since any mechanical constrictions in the blood stream provide a potential site for mechanical failure as well as sedimentation of blood and thrombosis. Hence, this system, which does not require a valve system, can be highly advantageous.
[0026] In addition, the compression frequencies of this system can operate below 5 cycles per second. This has an advantage over modern blood pumps that may require up to 90000 rotations per minute/1500 cycles per second of up to 16 blades to propel the blood.
[0027] Unlike peristaltic pumps, this pump does not necessarily implement complete squeezing or forward displacing by a squeezing action. Complete squeezing might introduce thromboginity. In addition, when used with live animals, the lack of complete squeezing means that any organism smaller than the smallest opening will likely be unharmed by any operation of the pump.
[0028] The system also does not require any permanent constrictions such as hinges, bearings and struts. This therefore provides an improved “wash out” condition. Again, such a condition can avoid problems such as thrombosis. The elastic energy storage concept can be extremely efficient, and can be used for total implantibility in human body possibly driven by a natural energy resource such as body heat and muscle action. Implanted or external elements based on the Peltier effect can be used to convert the body heat to the electricity needed to drive the pump. Also, mechanical to electrical energy converters based on piezoelectric elements, for example can be used to harvest mechanical motion of the muscles.
[0029] Although only a few embodiments have been described in detail above, many modifications are possible and contemplated. For example, the shape of the chambers A and B can be modified to improve elastic characteristics and storage capacity of the pump. The chambers A and B need not be the same size and need not be cylindrical. Once optimized, each total segment can be arranged either in series or in parallel to change the working pressure or volume flux. The method of operation via pinching can be made asymmetric in order to provide a non-uniform displacement to achieve better performance. As alternatives to the pneumatic actuator, a linear motor or cam system can be used to actuate the segment P. Skeletal or artificial muscles could be used.
[0030] The tubes can be any material of tube, such as polyethylene, or body fluid resistant plastic. The “tubes” need not be round, but could be any shape cross section. Also, the reducing element could be any other structure which can change the fluidic characteristics asymmetrically.
[0031] All such modifications are intended to be encompassed within the following claims, in which:
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A pump formed from an asymmetric tube, which is pinched to form asymmetric forces, that pump fluid.
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FIELD OF THE INVENTION
This disclosure pertains in general to a composite exterior siding panel that includes a system for interlocking panels that facilitate the downward movement of moisture away from the building structure. The disclosure also details how the system of interlocking panels limits the ability of wind to undermine the panels creating pressure differentials on the front and back surface that can dislodge the panel from the structure.
BACKGROUND OF THE INVENTION
Siding panels serve a two-fold objective of protecting a structure from damaging elements such as sunlight, moisture, hail and strong winds as well as providing an aesthetically appealing external appearance to the structure. The siding must be capable of protecting the structure from blisteringly hot sunlight that can induce thermal expansion and unattractive buckling of the siding. Siding produced from polyvinyl chloride (PVC) with organic and inorganic fillers has been shown to minimize thermal expansion and prevent or minimize the buckling of the siding when the solar heat load upon the structure is the greatest. The thermally stable siding is blended with high quality materials and is extruded with sufficient thickness to withstand large diameter hail impacts without permanent deformation. Panel siding must also minimize the infiltration of moisture from heavy wind blown rains and should moisture find its way behind the siding an exit route must be available to avoid the growth of mold and to prevent the rotting of any cellulosic structural elements such as plywood siding and structural framing or the oxidation of ferrous support members.
In addition to the capacity to withstand thermal loading, hail impacts and provide an escape route for moisture, well designed and installed exterior siding must be capable of withstanding high wind loadings. Siding panels that allow wind to gain access to the back surface, or the surface adjacent to the building structure, can experience tremendous loads capable of literally peeling the siding from the building. Consequently, the ability to seal both the upper and lower edges of the siding panel against panel courses above and below is critical to protecting the panels from the effects of strong wind loads.
Numerous siding panel designs exist in the market place; however, all are either lacking in some functional aspect or are prohibitively expensive, difficult to install or require extensive training and costly tools for proper installation. The consequence of such involved training and the acquisition of expensive tools is that these costs must ultimately be passed onto the consumer in order for the installer to experience a profit from her labors.
The product disclosed herein overcomes the adversities posed by wind, hail, rain, sun and complex installation procedures with a simple design that requires little training or sophisticated tools to properly install. In addition, the handsome wood grain exterior surface is aesthetically appealing with the warm textured feel of natural wood yet produced from a composite material that is highly resistant to fading, chipping, moisture damage, cracking and damage by insects.
It is an object of the invention to provide a composite exterior siding panel that is thermally stable and that will not buckle or warp even under the most extreme solar heat loads.
It is another object of the invention to provide an aesthetically appealing exterior surface that replicates a natural wood grain.
It is another object of the invention to provide a composite exterior siding panel that is lightweight and easy to install by an untrained homeowner with standard tools.
It is another object of the invention to provide a composite exterior siding panel that is tough, durable and capable of withstanding impacts from large diameter hail.
It is another object of the invention to provide a composite exterior siding panel that facilitates drainage of moisture trapped between the paneling and the building structure through weep slots in the rear face of the panel that start near the first flat and proceed past the inflection point of the panel.
It is another object of the invention to provide a composite exterior siding panel that includes a locking leg extending rearwardly from the back face of the panel and that also extends nominally downwardly toward the bottom edge of the panel and that extends longitudinally along the entire length of the panel. The locking leg creates a pocket for insertion of the top edge of a second panel disposed below the first panel to precisely define the positional relationship between the first and second panels.
It is another object of the invention to provide a composite exterior siding panel with a top portion and a bottom portion of a panel separated by an inflection point such that the top and bottom portions diverge at approximately 5 degrees so that when the panel is secured to the side of a structure at the nail strip the panel portion below the inflection point extends away from the building surface. In addition, when installed against a structural wall, the bottom surface of the locking leg is separated from the structural wall by a gap of from 0.020 to 0.060. The gap between the locking leg and the surface of the wall facilitates movement of moisture from upper panel courses to lower panel courses and ultimately to ground level thereby limiting contact with building surfaces that would deteriorate if exposed to the moisture for extended periods of time.
SUMMARY
The composite exterior siding panel with interlock system disclosure is directed to a panel capable of protecting a structure from damaging elements such as sunlight, moisture, hail and strong winds as well as providing an aesthetically appealing external appearance to the structure. In a preferred embodiment the siding panel comprises an extruded composite material of polyvinyl chloride that includes a combination of organic and inorganic fillers that increase the panel's durability, resistance to mold growth, resistance to deformation from hail impacts and overall structural strength.
The disclosed siding panel comprises a panel with a front face and a back face along with a top edge and a bottom edge. As is typical with siding panels, the panel course above partially overlaps the panel course below and the description below effectively outlines a system for building multiple courses of panels stacked atop and interlocking with one another on the side of a building.
The disclosed siding panel also includes a top portion of the panel and a bottom portion, the top and bottom portions of the panel diverge from one another at an inflection point. These diverging panel portions facilitate the formation of a path for moisture to travel between panel courses as will be discussed in greater detail below. The disclosed siding panel includes a flange extending substantially perpendicularly from the back face of the panel adjacent the bottom edge as well as a locking leg with a flat pad. The flange and locking leg with a flat pad run longitudinally along the entire length of the panel as do all features described below unless otherwise noted.
The locking leg backside in concert with the back face of the panel form a pocket for insertion of the top edge of a separate panel positioned in a lower panel course. The composite panel also includes a nail strip extending longitudinally along the entire front face of the panel proximate the top edge of the panel to be used in securing the panel to the wall with nails, screws and other securement means. The panel also includes a full contact strip extending longitudinally along the entire back face of the panel proximate the top edge of the panel which serves as the panel's only longitudinally extending area of contact with the wall surface.
After the first course of paneling is applied to the structure the pocket formed by the locking leg backside and the back face of the panel on the second course is positioned over the top edge of the first panel secured to the structure. Once the top edge of the first panel is positioned within the locking leg pocket of the second course, the second course is secured to the structure through the nail strip causing the full contact strip to lay flat against the structure. When a panel is secured to the structure at the full contact strip the entire back face of the panel below the inflection point, including the flat pad of the locking leg, raises off of the structure. Since no features of the back side of the panel below the inflection point are in contact with the wall surface an unobstructed path is created for moisture to flow downward with the aid of gravity.
Once moisture reaches the next lowest panel course it encounters the bottom edge of the first flat proximate the top edge of the panel where weep slots are installed to further facilitate the movement of moisture downward. The weep slots are installed with a separation distance of between 3 and 16 inches with a preferred diameter of about 3/16 inch. The weep slots originate proximate the bottom edge of the first flat and extend past the inflection point thereby allowing moisture to travel past the full contact strip which is firmly pressed against the wall by nails or screws passing through the nail strip. Failing to include weep slots would cause moisture to pool atop the first flat thereby potentially contributing to deterioration of the wall structure due to mold growth or structural member damage. Additionally, without weep slots moisture could become trapped behind the panel during a freeze thaw cycle thereby causing the moisture to expand and push the panels away from the structure loosening the connection to the building.
An additional feature of the disclosed panel is a flange extending substantially perpendicularly from the back face of the panel adjacent the bottom edge. When a second and further courses are installed the flat of the panel flange positioned above lands squarely and firmly on the front face of the lower panel course. The flange serves an aesthetic purpose of simulating a real wood panel that has sufficient thickness to overlap the panel course positioned below. Additionally, the flange serves to limit the intrusion of both high speed winds and wind blown moisture. High speed winds that enter beneath the bottom edge of panels that are not secured at the nail strip can catastrophically peel one or many panels from the wall surface. The flange effectively provides a wind and rain shield keeping the elements from intruding behind the panels and allowing the front face of the panel to provide protection for the structure.
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the siding panels secured to the side of a building;
FIG. 2 is a perspective view of a portion of an embodiment of a single panel;
FIG. 3 is a side elevation view of an embodiment of a single siding panel;
FIG. 4 is a side elevation view of an embodiment of two interlocked siding panels;
FIG. 5 is a side elevation view of an embodiment of two interlocked siding panels secured to the side of a building; and
FIG. 6 is a rear perspective view of an embodiment of a single siding panel revealing a weep slot.
DETAILED DESCRIPTION
FIG. 1 illustrates a structure 12 with several courses of exterior siding panels 10 installed thereon. The siding panels 10 can be extruded in many different widths with 4 and 7 inches the industry preferred panel widths. The panels are installed beginning at the lowest level and courses are installed progressively higher until the desired portion of the wall 38 is covered. The panels 10 are preferably extruded using a polyvinyl chloride composition with organic and inorganic fillers that contribute to thermally stabilizing the panels so that when exposed to intense solar heat the panels do not substantially expand and contract causing problems with panel buckling and loosening of the nails that anchor the panels 10 to the building wall 38 . The polyvinyl chloride in conjunction with the specially formulated organic and inorganic fillers produces a mechanically tough and resilient panel that is resistant to deformation from impacts such as hail and thrown objects as well as being resistant to insect damage and mold growth.
As seen in FIG. 2 , the panel 10 is comprised of a front face 16 and a back face 18 opposite the front face. The front face 16 and the back face 18 are separated by a panel thickness 20 that is in the range of from 0.25 to 0.35 inches and preferably about 0.280 inches; however, this thickness may be optimized depending upon the width of the panel that is being produced. This thickness of the material provides sufficient structural rigidity to keep the panels from permanently deforming during severe hail storm events yet is sufficiently thin to minimize the weight of a long panel thereby facilitating ease of installation. The front face 16 of the panel is preferably texturized to simulate natural wood grain; however, smooth untexturized surfaces are also an option.
All features described below run the entire length of the panel 10 unless otherwise stated. As best seen in FIGS. 3 and 4 , the panels include a top edge 22 and a bottom edge 24 opposite the top edge. The top of the panel 10 includes a first flat 26 angled at approximately 35 degrees from the plane of the back face 18 that, when installed, rests in the pocket 28 formed by the locking leg 30 of panel B as seen in FIG. 4 , disposed immediately above the first panel A. The first flat 26 rests against the inner surface 64 of the locking leg 30 and is used to control the vertical positioning of panel B that is being positioned atop panel course A. On the opposite side of the top edge 22 from the first flat 26 , as seen in FIG. 4 is a second flat 34 that when interlocked with panel B rests against the back face at 68 immediately below the locking leg 30 . The second flat 34 serves to further stabilize the bottom portion of panel B and provide the panel course located above with rigidity as it is disposed beneath the locking leg 30 .
Below the top edge 22 of the panel 10 is a point of inflection 36 separating the panel into a top portion 56 and a bottom portion 58 that directionally diverge from one another at an angle in the range of between 3 and 7 degrees. The inflection angle is preferably 5 degrees; however, this angle may vary depending upon the specific dimensions of the panel 10 .
At the bottom edge 24 of the panel 10 is a flange 40 extending substantially perpendicularly from the back face of the panel adjacent the bottom edge 24 . The flange 40 has a flange face 60 that when the panel is in position against the wall rests atop the front face 16 of the top portion 56 of the panel 10 as shown at reference number 74 . In addition to the flange 40 , and as previously discussed, is a locking leg 30 in proximity to the bottom edge 24 extending outwardly from the back face 18 and in the direction of the bottom edge 24 . The locking leg 30 includes a front side 62 , a back side 64 and a flat 66 . As discussed above, the locking leg back side 64 in conjunction with a segment 68 of the panel back face forms a pocket 28 for insertion of the top edge 22 , first flat 26 and second flat 34 of panel A positioned therebelow. The pocket 28 has a radius in the range of 0.040 to 0.080 inches and preferably a radius of 0.060 inches.
As best seen in FIG. 5 , the bend in the panel at the inflection point 36 causes the lower portion of the panel 58 to rise up off of the wall 38 leaving the wall untouched by the panel beneath the inflection point 36 . Even the locking leg flat 66 remains out of contact with the wall 38 with the panel inflection producing a gap G between the wall and the locking leg flat 66 in the range of 0.025 to 0.0375 inches. This gap G between the locking leg flat and the wall is preferably 0.030 inches to facilitate the drainage of water down the wall 38 past the panel backside and the locking leg flat 66 .
As seen in FIG. 2 , at the opposite end of the panel near the top edge 22 is a nail strip 44 that extends longitudinally along the entire front face 16 of the panel. The nail strip 44 has at its center a score line 46 into which the tips of nails should be hammered or screws threaded into the structural wall 38 behind the panel 10 as visualized in FIG. 5 . On the back face 18 of the panel 10 opposite the nail strip 44 is a full contact strip 48 extending longitudinally along the entire back face 18 of the panel 10 . The full contact strip 48 has an upper boundary 70 and a lower boundary that is coincident with the inflection point 36 defining the width of the strip. The full contact strip 48 is a flat strip that rests against the wall 38 when the panel 10 is secured to the wall 38 with nails or screws.
As best seen in FIG. 6 , weep slots 50 are also included on the back face 18 of the panel 10 to facilitate the transfer of moisture away from behind the panels. These weep slots 50 begin at the upper boundary 70 of the full contact strip 48 and extend downwardly past the inflection point 36 where they terminate in the panel bottom portion 58 away from the wall 38 .
In operation, a first course of paneling 10 is positioned against the lower level of the structural wall 38 and confirmed to be level. Next, nails, screws or other appropriate securement means are used to secure the full contact strip 48 of the first panel firmly against the wall 38 through the score line 46 in the nail strip 44 on the front surface 16 . As previously discussed, the panel 10 utilizes an inflection point 36 that produces directional divergence between the panel top portion 56 and the panel bottom portion 58 in the range of between 3 and 7 degrees and preferably at about 5 degrees. Consequently, nailing the panel to the wall 38 such that the full contact strip 48 is positioned against the wall 38 causes the panel bottom portion 58 , including the locking leg 30 , to raise up off of the wall 38 . Moisture can exit the area of the first flat 26 by passing through the weep slots 50 which are preferably spaced apart from 3 to 16 inches thereby giving trapped water an opportunity to escape. This moisture moves along the same path past each successive panel until it reaches the lower most surface of the structure where it is discharged to the ambient environment.
Once the first course A is secured to the wall, the locking leg 30 of the second course B is placed over the top edge 22 of the first course A. The locking leg of the second course panel effectively holds the second course in position atop the first course and since the first course A was previously leveled the second course B will remain level. The top edge 22 , first flat 26 and second flat 34 all cooperatively engage with the pocket 28 behind the locking leg 30 to form a rigid and secure interlock between successive courses of panels.
Another functional feature of the overall panel design is the flange 40 located at the bottom edge 24 . The flange face 60 serves to contact the top portion 56 front face 16 as shown at reference number 74 . The flange 40 also serves to prevent or greatly limit the infusion of air behind the panel 10 during strong wind events which can result in the panel being ripped from the surface 38 of the building. Additionally, the flange 40 greatly minimizes or prevents the infusion of water during rain storm and high wind events that can lead to water being trapped behind the siding saturating cellulose based building materials that can rapidly grow mold causing environmental as well as structural problems.
While the preferred form of the present invention has been shown and described above, it should be apparent to those skilled in the art that the subject invention is not limited by the figures and that the scope of the invention includes modifications, variations and equivalents which fall within the scope of the attached claims. Moreover, it should be understood that the individual components of the invention include equivalent embodiments without departing from the spirit of this invention.
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Disclosed herein is an interlocking siding panel system for securing to the side of a structure with planar surfaces. When the panel is secured to the structure through the nail strip a full contact strip opposite the nail strip lays flat against the structure causing the panel portion below an point of inflection in the panel to raise up off of the structure creating a gap to facilitate movement of moisture past a locking leg that integrates with the panel below.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A “SEQUENTIAL LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to a rotary grinder with an improved modular and/or split apart design.
[0006] 2. Description of the Related Art
[0007] Rotary grinders with forced horizontal feed are known. Typically, they are designed to have a ram compartment with a lower compartment plate serving as a lower portion of a hopper of the grinder. A reciprocating ram, typically horizontally driven by a hydraulic piston system, has a vertically situated ram slidingly resting on the horizontally situated lower compartment plate and forces material from the hopper to a rear power head having a rotor with teeth for reducing the material in the hopper. Other feed systems such as roller feeder systems have been used wherein the material is fed to the rotor between a pair of opposing rollers.
[0008] Typically, the rotary grinders of the prior art are of a unitary structure wherein sidewalls of the grinder extend from the front compartment to the rear power head. Such a configuration makes it difficult or impossible to custom assemble a rotary grinder having a selected front compartment with a selected rear power head or to change the configuration of the rotary grinder once having been manufactured. Additionally, these unitary rotary grinders have lacked modular components and assemblies that can be replaced with the same or different components for maintenance or reconfiguration of the rotary grinder. Furthermore, the unitary configuration of the prior art rotary grinders makes it difficult to access parts and components for maintenance, repair, or replacement such as replacing teeth on the rotor or adjusting a counter knife.
SUMMARY OF THE INVENTION
[0009] Rotary grinders of embodiments of the present invention are, for example, used to grind plastic, carpet, wood or other solid materials to reduce the size of the material to a desired size. The rotary grinder may also be used to reduce material such as film, fibrous material and other materials which have a tendency to wrap around the rotor. The materials to be shredded are placed into a hopper or other feeding mechanism such as opposed cylindrical rollers. In an embodiment having a hopper, a reciprocating ram is used to drive the material toward a counter knife horizontally situated with the longitudinal axis of the rotor. The rotor has a plurality of cutters removably mounted thereon. When in use, the ram travels from its open position near the front end of the rotary grinder across the hopper floor or lower compartment plate towards the rotor, pushing material towards the rotor and counter knife. As the rotor revolves about its axial shaft, the cutters on the rotor engage the material in the hopper drawing the material downward towards the counter knife. The counter knife has a cutting edge with interstices that closely receive the cutters on the rotor. The material is cut into pieces between the cutters and the counter knife.
[0010] Embodiments of the present invention for a rotary grinder have an improved modular and/or split apart configuration. The modular configuration has a separate front compartment assembly and rear power head assembly. The front compartment assembly has modular components such as a ram assembly, component sidewalls, and a support frame assembly. Other optional components include a hydraulic system for separating the front compartment assembly from the rear power head assembly and electronic sensors and control component assemblies. The rear power head assembly has modular components such as a rear power head frame supporting a modular right and left power head wall, an anvil, a rotor, a gear box, and a motor. Each of these component parts may have subcomponents and may be removed and replaced with the same or different component, subcomponent, or assembly making the modular rotary grinder transformable for different grinding needs or serviceable by the replacement of component parts.
[0011] In a split apart configuration, a front compartment assembly has a front compartment and a ram assembly where the front compartment is defined by a lower compartment plate and upward extending compartment sidewalls proximate each longitudinal edge of the lower compartment plate. The compartment plate and sidewalls are supported with a modularized front compartment frame. A ram assembly has a vertically oriented ram with a lower edge proximate the horizontally situated compartment plate and side edges proximate each sidewall. Each compartment sidewall has a front mating edge for engagement with rear mating edges on sidewalls of a rear power head assembly. An anvil extends between the lower end of the rear mating edges of the power head assembly sidewalls and is engageable with the lower compartment plate. Engagement of the mating edges and the anvil with the lower compartment plate forms a compartment having a rotor in a rear portion thereof and disengagement of the mating edges and anvil from the lower compartment plate provides for working space between the rear power head assembly and the front compartment assembly. A retainer assembly has a portion on the front compartment assembly and a portion on the rear power head assembly for removably retaining the front compartment assembly with the rear power head assembly.
[0012] The front compartment can be slidingly engageable with the rear power head assembly or the front compartment may be hingedly cooperable at a front of the compartment plate enabling the rear of the compartment plate to swing upwardly providing a working space between the rear power head assembly and the front compartment assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A better understanding of the invention will be had upon reference to the following description in conjunction with the accompanying drawings wherein:
[0014] FIG. 1 is a perspective view of a modular rotary grinder having a slide apart design showing a rear power assembly and a front compartment assembly having a hopper partially removed and a ram in retracted position;
[0015] FIG. 2 is a perspective view of the modular rotary grinder of FIG. 1 having the front compartment assembly slid apart from the rear power assembly;
[0016] FIG. 3 is a perspective view of the modular rotary grinder of FIG. 1 having the front compartment assembly slid apart from the power assembly showing a compartment assembly end of a retainer assembly for removably retaining the front compartment assembly to the rear power assembly;
[0017] FIG. 3A is a cut-away view of the modular rotary grinder of FIG. 3 showing the front compartment assembly end of a retainer assembly;
[0018] FIG. 4 is a perspective view of the modular rotary grinder of FIG. 1 having the front compartment assembly slid apart from the power assembly showing a rear power head end of a retainer assembly for removably retaining the front compartment assembly to the rear power assembly;
[0019] FIG. 4A is a cut-away view of the modular rotary grinder of FIG. 4 showing the rear power head assembly end of a retainer assembly;
[0020] FIG. 5 is a rear lower perspective view showing the modular rotary grinder of FIG. 1 ;
[0021] FIG. 5A is a cut-away from FIG. 5 showing the components of a grinder control system;
[0022] FIG. 5B is a rear lower cutaway view of a portion of the compartment assembly and frame showing an embodiment of a slidingly engagement therebetween;
[0023] FIG. 6 is a perspective view of a rear power head assembly showing rear mating edges and a rear bumper plate;
[0024] FIG. 7 is a perspective view of a front compartment assembly showing front mating edges and a front bumper plate;
[0025] FIG. 7A is a cut-away from FIG. 7 showing a portion of a retainer assembly;
[0026] FIG. 8 is a cutaway perspective view of a rear power head assembly and a front compartment assembly showing internal components thereof; and
[0027] FIG. 9 is a perspective view of an embodiment of the modular grinder having a front hinged compartment assembly.
DETAILED DESCRIPTION
[0028] While this invention is susceptible of embodiments in many different forms, there are shown in the Figures and will herein be described in detail, embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, and is not intended to limit the broad aspects of the invention to the embodiments illustrated.
[0029] With reference to FIG. 1 , modular single shaft rotary grinder 100 is shown having a rear power head assembly 103 and front compartment assembly 102 matingly engaged. Rear power head assembly 103 comprises power head frame 116 supporting modular component parts of power head assembly 103 . Component parts of power head assembly 103 include motor 152 attached to a lower part of housing assembly 116 and in mechanical cooperation with gear box 146 . Gear box 146 is also in mechanical cooperation with rotor 106 and transfers power from motor 152 to rotor 106 . Right lower power head wall 105 and left lower power head wall 107 each have an aperture for receiving an axial end of rotor 106 . In this embodiment, right and left power head walls 105 and 107 have a vertical opening above the axial ends of rotor covered with plate 171 . Plate 171 is removable permitting the vertical removal of rotor 106 with left and right power head walls 105 and 107 attached to power head frame 116 . Right power head walls 105 and 107 have a rear mating edge 142 . Moveable anvil 136 (shown in FIG. 3A ) movably extends between right and left lower power head walls 105 and 107 proximate a front lower portion of rotor 106 . Counter knife 109 moveably attaches to a top surface of anvil 136 and has a contoured blade adjacent rotor 106 closely receiving cutters 131 removably extending from an outer cylindrical surface of rotor 106 as rotor 106 rotates. Upper rear wall 108 is joined with and situated between upper right wall 113 and upper left wall 111 forming a rear portion of a hopper. Upper rear wall 108 is shown in this embodiment as sloping, but may be vertical.
[0030] Front compartment assembly 102 has front compartment 114 and a ram assembly ( 115 , FIG. 5 ) supported by modular front compartment frame 101 having a plurality of compartment supporting legs 104 extending between two longitudinally extending supporting beams. Front compartment 114 is defined by lower compartment plate 112 and an upward extending lower sidewall 118 proximate each longitudinal edge of lower compartment plate 112 . Lower compartment plate 112 has compartment plate lip 134 extending over movable anvil 136 . Lower sidewalls 118 each have a front mating edge 140 . Atop a rear modular section of each lower sidewall 118 extends an upper side wall 121 . Upper hopper assembly 110 is shown removed from upper sidewall 121 . When upper hopper assembly 110 is removably fastened to upper sidewalls 121 , a hopper is formed extending over front compartment plate 112 and rotor 106 . Upper right wall 113 , upper left wall 111 , and upper rear wall 108 form a rear section of the hopper over the rotor. Ram assembly 115 is covered with compartment top cover 128 and ram 119 (shown in FIG. 5 ) has compartment rear wall 123 extending upward therefrom when ram 119 is in a retracted position as is shown in FIG. 1 . Ram slide rail 124 longitudinally extends between each lower side wall 118 and upper sidewall 121 wherein an outwardly depending portion of ram 119 slides when ram 119 is longitudinally pushed or pulled to or from rear power head assembly 103 with a ram hydraulic system having ram hydraulic cylinder 138 . Preferably ram slide rails 124 have a polymeric lining reducing friction within ram assembly 115 . Lower side walls 118 modularly extend to the front of front compartment assembly 102 and have an outwardly extending flange 126 slidingly engaging compartment slide rails 127 . Outwardly extending flanges 126 and compartment slide rails 127 enable front compartment assembly 102 to be slidingly separated from rear power head assembly 103 . Preferably, the power to slide front compartment assembly 102 to and from rear power head assembly 103 is hydraulically supplied by an independent hydraulic system.
[0031] With reference to FIG. 2 , single shaft rotary grinder 100 is shown having a rear power head assembly 103 and front compartment assembly 102 in a split apart configuration. Rear power head assembly 103 comprises power head frame 116 supporting component parts of power head assembly 103 . Front compartment assembly 102 has front compartment 114 and a ram assembly 115 ( FIG. 5 ) supported by modular front compartment frame 101 . In this split apart configuration, worker 129 is availed space to enter between front compartment assembly 102 and rear power head assembly 103 to perform maintenance operations without the need to empty front compartment 114 of materials being ground. In this embodiment, front compartment assembly 102 slides apart from rear power head assembly 103 on modular front compartment frame 101 . The slide apart feature is provided with lower outwardly extending flange 126 extending outwardly from each lower longitudinal edge of front compartment assembly 102 slidingly engaging a compartment slide rail 127 . Preferably, surfaces of compartment slide rail 127 slidingly engaging flanges 126 are comprised of a polymeric material reducing the friction between front compartment assembly 102 and modular front compartment frame 101 when sliding front compartment assembly fore and aft of modular front compartment frame 101 . In this slide or split apart configuration, rear mating edges 142 and front mating edges 140 are separated and compartment plate lip 134 is removed from a top surface of anvil 136 . Cylindrical hydraulic ram 138 provides the force necessary to slide front compartment assembly 102 fore and aft of modular front compartment frame 101 .
[0032] In the split apart configuration as shown in FIG. 2 , worker 129 has easy access to modular components of power head assembly 103 and compartment assembly 102 for maintenance and/or replacement. For instance, rotor 106 may be cleared of debris, cutters on rotor 106 may be serviced or replaced, anvil 136 may be adjusted, and counter knife 109 may be replaced, serviced, or adjusted without the need to clear front compartment 114 of debris or disassemble portions of rotary grinder 100 to gain access to component parts. Additionally, access to modular parts such as motor 152 and gear box 146 is increased. In this view, removable belt 175 is shown cooperating with motor 152 and gear box 146 wherein motor 152 and gear box 146 are mounted to power head frame 103 in a parallel configuration. However, it is to be understood that motor 152 and gear box 146 may be in a right angle mount, have a fluid coupling and/or have a controlled torque coupling. The optional fluid coupling provides for a soft start while the controlled torque coupling protects against over torque as may be experienced with a rotor lock.
[0033] FIG. 3 shows modular rotary grinder 100 in a split apart configuration with a retainer assembly shown in detail in FIG. 3A . Rotary grinder 100 comprises rear power head assembly 103 having a power head frame 116 supporting a right lower power head wall 105 , a left lower power head wall 107 , an anvil 136 , a rotor 106 , a gear box 146 (shown in FIG. 1 ), and a motor 152 (shown in FIG. 1 ). Right lower power head wall 105 and left lower power head wall 107 each extend upward from power head frame 116 about each axial end of rotor 106 and have a rear mating edge 142 , anvil 136 movably extends between right and left lower power head walls 105 and 107 proximate a front lower portion of rotor 106 and has counter knife 109 moveably engaged on an upper surface thereof. Counter knife 109 may be adjusted closer to rotor 106 maintaining a close tolerance between cutters 131 and a cutting edge on counter knife 109 . Additionally, in the embodiment shown, counter knife 109 may be serviced or removed, rotated, and reinstalled onto anvil 136 placing an opposite cutting edge of counter knife 109 adjacent cutters 131 . This can be accomplished manually in the split apart configuration without the need to enter the hopper or compartment 114 .
[0034] Front compartment assembly 102 having front compartment 114 and ram assembly 115 where front compartment 114 is defined by lower compartment plate 112 and an upward extending lower compartment sidewall 118 proximate each longitudinal edge of lower compartment plate 112 . Front compartment assembly 102 is supported with a front compartment frame having supporting beams 117 interposed with supporting legs 104 . Lower compartment sidewalls 118 each have a front mating edge 140 that matingly engage a rear mating edge 142 on rear power head assembly 103 . Anvil 136 and lower compartment plate 112 are shown as being slidingly disengaged. Engagement of mating edges 140 and 142 and anvil 136 with lower compartment plate 112 forms compartment 114 having rotor 106 in a rear portion thereof and sliding disengagement of mating edges 140 and 142 and disengagement of anvil 136 from lower compartment plate lip 134 provides for working space between rear power head assembly 103 and front compartment assembly 102 . A retainer assembly 137 is shown in FIG. 3A has a portion on front compartment assembly 102 and a portion on rear power head assembly 103 . Each portion of the retainer assembly 137 is cooperable with the other portion enabling front compartment assembly 102 and rear power head assembly 103 to be securely engaged wherein front and front mating edges 142 and 140 are mated and anvil 136 is mated with compartment plate 112 . The portion of the retainer assembly 137 on front compartment assembly 102 may be a clamp rod sleeve 133 or a clamp rod fastener retainer 130 on an upper portion of each side of power head frame assembly 116 where front compartment assembly 102 has the other of clamp rod sleeve 133 or clamp rod fastener retainer 130 proximate each rear outer corner of compartment plate 112 . Clamp rod 132 extends through clamp rod sleeve 133 into clamp rod fastener retainer 130 and removably cooperates with fastener 135 removably retained in fastener retainer 130 . In the embodiment shown here, clamp rod 132 is a threaded bolt and fastener 135 is a nut threadingly engageable with threaded bolt 132 . Fastener retainer 130 may have a threaded portion therein eliminating the need for threaded bolt 132 . Also shown in FIG. 3A is compartment bumper plate 122 centrally depending from a lower side of compartment plate 112 which engages power head bumper plate 120 (shown in FIG. 5 ) centrally oriented on a front portion of power head frame 116 . Compartment bumper plate 122 engages power head bumper plate 120 when retainer assembly 137 securely engaged. Shown in FIG. 3 is optional horizontal plate 153 outwardly extending under bumper plate 122 wherein a top surface engages a lower surface of power head bumper plate 120 or other vertically supporting member on power head frame 116 . Also shown here is outer fixed seal ring 179 and inner rotating seal ring 181 having a close tolerance therebetween. Having inner rotating seal ring 181 with a larger diameter than rotor 106 substantially decreases or even eliminates materials being ground from lodging between axial ends of rotor 106 and sidewalls 105 and 107 . Pillow block bearing 177 is shown supporting an axial end of rotor 106 on power head frame 116 , however, any bearing or other friction reducing engaging means as is known in the art may support axial ends of rotor 106 . Preferably, pillow block bearing 177 is horizontally separable wherein a top portion can be removed allowing rotor 106 to be vertically removed.
[0035] FIGS. 4 and 4A show retainer assembly 137 having a portion on front compartment assembly 102 and a portion on rear power head assembly 103 . The portion of the retainer assembly 137 on power head frame assembly 116 has clamp rod sleeve 133 . Clamp rod 132 is in the form of a threaded bolt having the head of clamp rod 132 adjacent clamp rod sleeve 133 .
[0036] It is important to note that the fastening combination of retainer assembly 137 may be in a reverse orientation and still provide the function of fastening front compartment assembly 102 with rear power assembly 103 joining front mating edges 140 with rear mating edges 142 and compartment bumper plate 122 with power head bumper plate 120 . Additionally, other removable fastening combinations as is known in the art may be used to removably secure front compartment assembly 102 to rear power assembly 103 . An alternative embodiment of a power head wall is shown here wherein right and/or left power head walls are modular having an upper power head wall component 173 and a lower power head wall component 175 . The separation of upper power head wall component 173 and lower power head wall component 175 provides for the vertical removal of rotor 106 .
[0037] FIG. 5 shows a bottom perspective view of modular grinder 100 . In this view, rear power head bumper plate 120 is in an aligning relationship with front compartment bumper plate 122 . When front compartment assembly 102 and rear power assembly 103 are in an engaged position with front mating edges 140 mated with rear mating edges 142 , rear power head bumper plate 120 and front compartment bumper plate 122 become engaged. Therefore, rear power assembly 103 and front compartment assembly 102 are held together in a stable linear relationship with the central engagement of retainer assembly 137 , upper engagement of front mating edges 140 with rear mating edges 142 , and lower engagement of power head bumper plate 120 with front compartment bumper plate 122 . Also shown in this figure and detailed in FIG. 5 A are components of an embodiment of a grinder control mechanism having a ram position sensor rail 158 with slots 160 . Ram position sensor rail 158 is attached to ram assembly 115 having ram 119 on a rear end thereof and moves fore and aft of front compartment assembly 102 pushing materials toward rotor 106 . Sensor 156 and ram position sensor rail bracket 150 are mounted atop ram position sensor mount 148 and senses the position of ram sensor rail 158 via slots 160 and sends a signal through cable 154 to an external electronic control system (not shown). Ram assembly 115 has ram 19 vertically oriented and extending between lower compartment sidewalls 118 and up from lower compartment plate 112 . Ram sensor rail 158 is attached to ram assembly 115 and moves therewith, therefore ram sensor 156 senses the position of ram 119 . Other embodiments of a grinder control mechanism include laser or sonar sensor mechanisms having limit, velocity, and position controls.
[0038] FIG. 5B shows an alternative embodiment of elements for slidingly cooperation between front compartment assembly 102 and modular front compartment frame 101 . Supporting leg 104 supports supporting beams 117 . Supporting beams 117 support notched slide 162 , preferably comprised of a polymeric material. Outwardly extending flange 126 has longitudinally extending upper slide 159 with longitudinally extending guide 161 attached to a lower surface thereof. Preferably, upper slide 159 and guide 161 are comprised of a metallic material slidingly engaging notched slide 162 . Also shown here is an optional lateral support feature comprising guide 155 and guide retainer 157 . Guide 155 longitudinally extends supporting beam 117 and has an outwardly extending upper end. Guide retainer 157 longitudinally extends and is attached to flange 126 and extends around guide 155 providing slidingly lateral support between front compartment assembly 102 and front compartment frame 101 .
[0039] FIG. 6 is a perspective view of rear power head assembly 600 showing rear mating edges 142 and power head bumper plate 120 . Rear power head assembly 600 comprises power head frame 116 supporting modular component parts of power head assembly 600 . Right lower power head wall 105 and left lower power head wall 107 are each about an axial end of rotor 106 and have a rear mating edge 142 . Preferably, left and right lower power head walls 105 and 107 each have removable modular upper half or a slot in an upper half allowing for the vertical removal of rotor 106 without the removal of power head walls 105 and 107 . Rotor 106 is shown here as having tool holders 143 extending from an outer cylindrical surface thereof for supporting cutters thereon. Moveable anvil 136 movably extends between right and left lower power head walls 105 and 107 proximate a front lower portion of rotor 106 . Counter knife 109 moveably attaches to a top surface of anvil 136 and has a contoured blade adjacent rotor 106 closely receiving cutters attached to tool holders 143 as rotor 106 rotates. Upper rear wall 108 is joined between upper right wall 113 and upper left wall 111 forming a rear portion of a hopper. Upper rear wall 108 is shown in this embodiment as sloping, but may be vertical. Also shown here is optional guide block 163 extending from upper left power head wall 111 which engages an outer surface of upper side compartment wall 121 when front compartment assembly 102 engages rear power head assembly 103 .
[0040] FIG. 7 is a perspective view of a front compartment assembly 700 showing front mating edges 140 and front bumper plate 122 . Front compartment assembly 102 has front compartment 114 and a ram 119 supported by modular front compartment frame 101 having a plurality of compartment supporting legs 104 extending between two longitudinally extending supporting beams. Front compartment 114 is defined by lower compartment plate 112 and an upward extending lower sidewall 118 proximate each longitudinal edge of lower compartment plate 112 . Lower compartment plate 112 has compartment plate lip 134 extending beyond lower sidewalls 118 . Lower sidewalls 118 each have a front mating edge 140 . Atop a rear modular section of each lower sidewall 118 extends an upper side wall 121 , also having front mating edge 140 . FIG. 7A is a cut-away portion of the front compartment assembly 700 of FIG. 7 showing ram slide rail 124 longitudinally extending between each lower side wall 118 and upper sidewall 121 wherein an outwardly depending portion of ram 119 slides when ram 119 is longitudinally pushed or pulled to or from a rear power head assembly with a ram hydraulic system. Hydraulic cylinder 139 is a part of an embodiment of a separate hydraulic system for sliding front compartment assembly 102 on front compartment frame 101 . Preferably ram slide rails 124 have a polymeric lining reducing friction within ram assembly 115 . Lower side walls 118 have an outwardly extending flange 126 slidingly engaging compartment slide rails 127 . Optionally, outwardly extending flange 126 is a removable component part of sidewall 118 . Outwardly extending flanges 126 and compartment slide rails 127 enable front compartment assembly 702 to be slidingly separated from a rear power head assembly 103 .
[0041] FIG. 8 is a cutaway perspective view of a rear power head assembly and a front compartment assembly showing internal components thereof. Modular single shaft rotary grinder 800 is shown having a rear power head assembly 803 and front compartment assembly 802 in a split apart configuration. Rear power head assembly 803 comprises power head frame 116 having gear box 146 attached thereto. Gear box 146 is in mechanical cooperation with rotor 106 and transfers to rotor 106 . Moveable anvil 136 movably extends between right and left lower power head walls proximate a front lower portion of rotor 106 . Counter knife 109 moveably attaches to a top surface of anvil 136 and has a contoured blade adjacent rotor 106 closely receiving cutters depending from an outer cylindrical surface of rotor 106 as rotor 106 rotates. Upper left wall 111 and upper rear wall 108 form a rear portion of a hopper. Power head bumper plate 120 is shown centrally oriented within power frame 116 .
[0042] Front compartment assembly 802 has front compartment 114 and ram assembly 115 supported by modular front compartment frame 101 having a plurality of compartment supporting legs 104 extending from longitudinally extending supporting beams 117 . Front compartment 114 is defined by lower compartment plate 112 and an upward extending lower sidewall 118 proximate each longitudinal edge of lower compartment plate 112 . Lower compartment plate 112 has compartment plate lip 134 which extends over movable anvil 136 when front compartment assembly 802 is mated with rear power assembly 803 . Lower sidewalls 118 and upper sidewalls 121 each have a front mating edge 140 . Ram assembly 115 is covered with compartment top cover 128 and ram 119 has compartment rear wall 123 extending upward therefrom when ram 119 is in a retracted position as shown. Ram slide rail 124 longitudinally extends between each lower side wall 118 and upper sidewall 121 wherein an outwardly depending portion of ram 119 slides when ram 119 is longitudinally pushed or pulled to or from rear power head assembly 803 with a separate hydraulic ram system. Hydraulic cylinder 139 is a component part of a hydraulic system for sliding compartment assembly 102 for and aft front compartment frame 101 . Front compartment bumper plate 122 is shown centrally depending downward from a rear portion of compartment plate 112 for engagement with rear power head bumper plate 120 .
[0043] Also shown here are optional ram and compartment wiper assemblies. Rear wiper plate 149 is hingedly attached to compartment rear wall 123 with hinge 189 . Wiper 151 wipes an upper surface of ram assembly 115 when ram 119 is moved for and aft compartment plate 112 . Compartment cover 128 is modular in sections wherein a rear section can be removed allowing access to wipers 149 . Wipers 147 are adjacent an upper rear surface of ram 119 and have an outward force applied thereto wiping an inner surface of lower compartment side wall 118 . Wiper 145 extends a lower inner edge of ram 119 and wipes the upper surface of compartment plate 112 . Ram 119 can be extended beyond compartment 112 allowing access to pipers 147 and 145 .
[0044] FIG. 9 shows an alternative embodiment of the modular grinder of the present invention. Modular grinder 900 has front compartment assembly 902 and rear power assembly 903 . In this embodiment, front compartment assembly 114 rotates upward wherein front compartment plate lip 134 is raised from anvil 136 and the front lower corners of modular lower compartment sidewalls 118 are hingedly attached with hinges 926 to upper longitudinal supporting beams 117 . Upper supporting beams 117 horizontally extend atop compartment supporting legs 104 from front hinge attachments 926 and have front compartment assembly supports 927 thereon to engage outwardly extending flanges 126 . The upward rotation of front compartment assembly 902 provides working space between front compartment assembly 902 and power assembly 903 wherein rotor 106 , counter knife 109 , and other components of rotary grinder 900 can be serviced or replaced without the need to remove materials in front compartment 114 or the need to disassemble rotary grinder 900 .
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The present invention relates to a single shaft rotary grinder having a modular and/or split apart configuration. The modular configuration has assembly units and/or component parts that are interchangeable providing ease of construction of a rotary grinder having desired functionality for a specific application and/or providing ease of maintenance with the ability to replace worn or broken assembly units or component parts. The split apart configuration provides for the separation of a rear power head assembly and a front feeder assembly allowing easy access to the rotor and rear inner portion of the feed assembly.
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FIELD OF THE INVENTION
The invention relates to a preassembled step flashing strip for an imbricating roof.
BACKGROUND OF THE INVENTION
An imbricating roof of a structure meets a vertical surface, such as an off-set second story, chimney, skylight or roof elevation change, tile termination of each course of shingle commonly is an individual piece of metal (copper, galvanized steel or aluminum, for example) bent at or near a 90° angle. These pieces are combined with the individual shingle in such a way as to create an overlap intended to shed water. Such conventional step flashing offers a continual overlapping of individual pieces of material to form a water resistant termination of the shingle courses. Step flashing heretofore has been the most effective means for the termination of an imbricating roof system.
SUMMARY OF THE INVENTION
The tedious, labor intensive termination of shingle courses as described above can be improved with the step flashing strips of the present invention which comprises a plurality of flashing segments each having a pair of intersecting planar legs formed from or as a single piece, and a plurality of spacers which secure each flashing segment to an adjacent segment in spaced, partially overlapping relationship to allow for the insertion of a shingle between the overlapping region of adjacent segments.
In accordance with the present invention, after the first course of shingles come in contact with a vertical surface, the pre-manufactured strip of step flashing is laid down in the right angle corner. The shingles are then placed in the appropriate slots of the pre-manufactured strip and nailed in place.
The pre-manufactured strip or step flashing of the present invention (1) saves the installer time by reducing the handling of single pieces of material, (2) saves the installer time and material by reducing the number of fasteners needed to attach the strip flashing, and (3) as a result of reducing the number of fasteners used, fewer penetrations will occur in the roof, further reducing the possibility of leak(s) occurring.
A common mistake made with single step metal flashing is the use of different metal components such as an aluminum step flashing and galvanized roofing nail fasteners. With this mating of dissimilar metals, a galvanic action could occur corroding the aluminum and causing leak(s). As mentioned above, the reduction of fasteners needed when using the strip step flashing of the present invention reduces this application problem if galvanic action occurs.
This invention increases an installer's productivity and reduces labor costs in the application of step flashing with said surfaces by reducing handling, positioning and fastening.
An equally important advantage is the installer can use the strip step flashing as a guide for the chalk line that keeps succeeding shingle course parallel. Where the strip step flashing of the present invention is applied, the labor to measure and mark the roof deck for the parallel lines would be eliminated.
A further advantage is the reduction of possible errors made when the individual step flashings are installed, such as misplaced fasteners. Fasteners must be placed within about two inches from the top of each step flashing or the fasteners will be exposed to the weather and possibly resulting in failure.
The present invention would reduce the fasteners by as much as about 70 percent thereby reducing the potential for leakage.
An additional advantage is that the strip step flashing of the present invention can be manufactured to accommodate varying thicknesses of shingles as well as custom thickness of shingles for any imbricating roofing system.
The strip step flashing of the present invention can replace the standard metal seep flashing application technique without changing the established accepted appearance of the finished installation.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a structure showing typical application points for the step flashing strip of the present invention;
FIGS. 2 and 2A are perspective views of step flashing strips embodying the present invention;
FIG. 3 is a perspective view of a particular application showing the strip step flashing of FIG. 2 with a shingle in place;
FIG. 4 is a side elevation view of the strip step flashing of FIG. 2; and
FIG. 5 is a perspective view of an alternative embodiment of a step flashing strip formed by interlocking a plurality of extruded step flashing segments.
DETAILED DESCRIPTION OF THE INVENTION
Typical applications of the step flashing strip of the invention generally include any edge formed by the intersection of an imbricating roof and another planar surface. Examples, shown in FIG. 1, include the intersection 10 of an imbricating roof 12 with a vertical wall 14, the intersection 16 of an imbricating roof 18 with a chimney 20, the intersection 22 of the roof 16 with a skylight 24, and a roof valley formed by intersecting imbricating roof faces such as the valley 26 formed by the imbricating roof faces 12 and 28.
With reference to FIGS. 2 and 3, the step flashing strip 30 comprises a plurality of flashing segments 32 which are preferably secured one to another in spaced, partially overlapping relationship by a plurality of spacers 34. Each flashing segment 32 is formed from, or as, a single piece and has a pair of intersecting planar, preferably rectangular shaped, legs 36 and 38. The legs 36 and 38 are formed at, or bent to form, a predetermined custom or standard bend to provide an angle, such as 90° , between the legs. The segments which for any particular strip are substantially identical, are secured to one another in spaced partially overlapping to form two overlapping areas at each juncture between adjacent flashing segments. A first of the overlapping areas at each juncture is defined by the overlapping areas of legs 36 of adjacent segments 32. The second of the overlapping means at each juncture is defined by the overlapping areas of legs 38 of adjacent segments 32 relationship.
Spacers 34 act to secure adjacent segments 32 to each other in partially overlapping relationship to form an integrated or continuous, one-piece step flashing strip 30, and the spacers 34 also provide a gap or space 40 at the overlapping areas between adjacent segments 32 into which a shingle can be snugly inserted. A spacer 34 is situated such that it resides within at least one of the overlapping areas of each juncture between adjacent segments 32. The spacer 34 is situated contiguous with the intersection of legs 36 and 38 of at least one of the joined segments 32 such that it occupies substantially less than all of any overlapping area at which it resides to permit placement of a shingle between one or both of the overlapping areas between legs 36 and legs 38 of adjacent flashing segments 32. The spacers 34 can be designed to provide a space 40 for shingle insertion between either or both of the legs 36 and 38 of adjacent flashing segments 32 as shown in FIG. 2. The strip shown in FIG. 2 having spaces between adjacent legs 36 and 38 can be used, for example, at the valley 26 between two imbricating roof faces to allow for insertion of course terminal shingles on each side of the flashing. The strip shown in FIG. 2A having spaces only between adjacent legs 38 can be used, for example, between intersections 10, 16 and 22, wherein an imbricating roof face intersects with a nonroof surface such as a vertical wall, a skylight or a chimney. The spacers 34 can, for example, as shown in FIG. 2, be L-shaped strips which are of a length substantially equal to the length of the overlapping region of the legs 36 and 38 of adjacent flashing segments 32. Alternatively, the spacers 34a can, for example, as shown in FIG. 2A, be strips having a rectangular cross section with a length substantially equal to the length of the overlapping region of the legs 36 and 38 of adjacent flashing segments 32. However, generally any means, both for spacing the legs 36 and 38 of adjacent segments 32 to allow for shingle insertion, and for facilitating securement of adjacent segments 32 to provide a continuous, integrated or one-piece step flashing strip comprising a plurality of flashing segments, may be used.
The spacers 34 are preferably from about 1/8 inch to about 3/16 inch thick but in some cases may advantageously range from about 1/32 inch to about 2 inches in thickness depending on the thickness of the shingles to be used. The flashing segments 32 are preferably about 4 inches wide by about 7 inches long, but in some cases may advantageously range from about 1 inch to about 3 inches wide by about 1 inch to about 5 feet long. The thickness of the flashing segments 32 can range from about 2 mils to about 400 mils and is preferably from about 30 mils to about 200 mils. The overlap of the individual pieces is preferably from 2 inches to 19 inches but in some cases may advantageously range from 1/4 inch to 5 feet. The spacers 34 allow for the insertion of a shingle without deforming the legs 36 and 38 of flashing segments 32.
The strip 30 can have any desired number of segments 32 depending on the length of each segment, the amount of overlap between segments and the desired length of the strip. It is contemplated that the length of the step flashing strips will desirably range from about 4 feet to 12 feet.
A fastener opening 42 is preferably provided at the overlapped leg area of selected segments 32 or at each segment to rapidly facilitate proper placement of fasteners such as on screws or nails, and to eliminate or at least substantially reduce the possibility of splitting of the flashing segment 32 upon fastening the strip 30 to a roof.
Materials suitable for fabricating the flashing segments 32 and spacers 34 include metals such as aluminum, galvanized steel and copper; elastomers such as chlorosulfonated polyethylene (CSPE), ethylene propylene diene monomer (EPDM), chlorinated polyethylene (CPE), butyl rubber, styrene butadiene rubber (SBR), nitrile rubber, and the like; thermoplastics such as polyvinyl chloride (PVC) post chlorinated polyvinyl chloride (CPVC), acrylonitrile-butadiene-styrene resin (ABS), polyolefins such as polypropylene or polyethylene, acrylic polymers, and the like; and bitumens such as asphaltic compounds, rubberized aspbaltic compounds and coal-tar compounds. The spacers 34 can be of similar material to that of the flashing segments or dissimilar material.
The step flashing strips of the invention can be fabricated by forming the flashing segments 32 and spacers 34 together such as by casting, extruding, or by molding thermoplastic, thermosetting or metal materials. An extruded strip having angled legs and integrally formed spacers can be cut into appropriate lengths to form flashing segments 32 with integrally formed spacers, and then secured one to another. More preferably, the flashing segments 32 and spacers 34 can be formed by cutting a strip of material having the appropriate cross section into individual spacers 34 of appropriate length and separately forming the flashing segments as by molding or by cutting and bending sheet materials or by cutting an appropriately shaped extruded material into the individual segments 32. The spacers 34 and segments 32 are then joined to one another by various conventional means, depending upon the materials used, such as by adhesives, fusion or welding, to form the step flashing strips of the invention.
The strip step flashing 30 shown in FIG. 3 is ensconced at the junction of a vertical surface 44 and sloped roof. The spacer 34 allows the insertion of the shingle 48 into the strip step flashing without deforming the legs 38 of the individual step flashing segments. The fasteners 50 are typically placed over the cutout of the shingle in accordance with conventional practice. The strip 30 can be secured to the roof with fewer fasteners than conventional practice wherein a fastener is required for each flashing piece at the end of a shingle course. For example, it would be possible to use a fastener at every third or forth segment by lifting the corner of leg 38 and attaching a fastener through opening 42.
In an alternative embodiment, the individual segments 132 can be continuously extruded with cooperating, integrally formed interlocking spacer means 150 for attaching one segment to another to form a strip 130 as shown in FIG. 5 and for providing space between overlapping legs 132 and/or legs 136 of adjacent segments 132 of strip 130. Flashing segment 132 having legs 136 and 138 is generally similar to flashing segment 32 but has an interlocking spacer integrally formed with a keyshaped slot 160 and a cooperating key-shaped projection 162 which securely fits into the slot 160 of an adjacent segment 132 to form a strip 130 as shown in FIG. 5. The particular embodiment shown in FIG. 5 is only intended as illustrative of the concept of means for interlocking flashing segments in spaced, partially overlapping relationship to one another to allow for insertion of a shingle between each pair of adjacent segments. Various alternative means will be readily apparent to those skilled in the pertinent art, and accordingly are within the spirit and scope of the invention.
While in accordance with the Patent Statutes, the best mode and preferred embodiment has been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
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A step flashing strip having a plurality of flashing segments, secured to another segment in spaced overlapping relationship by a spacer to allow for the insertion of a shingle into the overlapping region between the segments, allows for a simplified, time saving method of providing a water shedding termination of an imbricating roof at its intersection with another surface.
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BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to a method and system for verifying migration of data. More specifically, as files are migrated to a different storage system metadata associated with the transferred file is verified.
2. Description of the Prior Art
In a multiprocessing computer system, a storage area network (“SAN”) is an increasingly popular storage technology. The SAN allows multiple computers to access a set of storage devices, also known as storage media. Often data may be migrated between filesystems hosted on different storage media through a computer network. The computer network may be a local area network, a wide area network, a telecommunication network, a computer component network, a message based network, or other functionally equivalent data transfer network system. Migration of data is common during a backup or restore operation. A source filesystem is the original filesystem storing the associated data, and a destination filesystem is the filesystem storing the transferred data. Each file and folder in the source filesystem is comprised of data and metadata. The data includes numerical or other information represented in a form suitable for processing. The metadata includes information pertaining to the size, creation time, last modification time, and security attributes of the file and/or folder. When a file and/or folder is transferred from the source filesystem to the destination filesystem, both the data and metadata are required to accompany the transfer.
At such time as a transfer of a file and/or folder between filesystems, an operator may specify that all or a portion of the associated metadata accompany the transferred file. If the source and destination filesystems are different, there is an increased likelihood that there may have been an incomplete transfer of the associated metadata. Although there are tools that synchronize two file sets, the prior art does not provide a tool that detects differences in metadata of the two file sets to verify that the metadata was correctly preserved during the transfer from the source filesystem to the destination filesystem. In addition, current data transfer tools do not ensure preservation of transferred metadata of the creation time and last modification time, nor do they allow the user to verify correct preservation of the metadata during the data transfer. Prior art solutions for checking preservation of transferred metadata require a manual check of corresponding files and folders in both the source and destination filesystems. However, the prior art does not provide a tool that supports an automated verification of metadata of all files and folders at both the source and destination filesystem locations.
Accordingly, there is a need for an automated tool that validates the integrity of metadata at both the source and destination filesystem locations of all transferred files and folders.
SUMMARY OF THE INVENTION
This invention comprises a method and system for maintaining the integrity of file metadata during a migration of the file between filesystems.
In one aspect of the invention, a method is provided for verifying preservation of metadata. Metadata of a file from a source filesystem location is compared with metadata of the file at a destination filesystem location. Thereafter, a test is conducted to determine if the metadata of the file from the source filesystem is equivalent to the metadata of the file at the destination filesystem.
In another aspect of the invention, a computer system is provided with two filesystems. A file having data and metadata is provided from a source filesystem location, and a file having data and metadata is provided at a destination filesystem location. A director is employed to compare the source filesystem metadata with the destination filesystem metadata, and to determine if the metadata of the file from the source filesystem is equivalent to the metadata of the file at the destination filesystem.
In yet another aspect of the invention, an article is provided with a computer readable storage medium. Means in the medium are provided for storing metadata of a file from a source filesystem location, and for storing metadata of a file at a destination filesystem location. In addition, means in the medium are provided for comparing metadata of the file from the source filesystem location with metadata of the file at the destination filesystem location, and for determining if the metadata of the file from the source filesystem is equivalent to the metadata of the file at the destination filesystem.
Other features and advantages of this invention will become apparent from the following detailed description of the presently preferred embodiment of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 c are a flow chart illustrating a process for verifying migrated data.
FIG. 2 is a flow chart illustrating a process for comparing time for a file at two filesystem locations.
FIGS. 3 a and 3 b are a flow chart illustrating a process for determining time resolution for creation time in a filesystem.
FIGS. 4 a and 4 b are a flow chart illustrating a process for comparing file creation time of a file at two filesystem locations.
FIGS. 5 a and 5 b are a flow chart illustrating a process for determining time resolution for a last write time of a file in a filesystem.
FIGS. 6 a and 6 b are a flow chart illustrating a process for comparing a last write time of a file at two filesystem locations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Overview
During the course of transferring a file from a source filesystem to a destination filesystem, both data and metadata are transferred. In order to determine if the transfer of data was complete, a review and comparison of the metadata of the destination file and/or folder with the metadata of the source file and/or folder is conducted. Metadata associated with each file and folder in both the source and destination file systems is compared. If any of the metadata elements associated with each file and/or folder in the source or destination filesystem does not match, the comparison fails.
Technical Details
FIGS. 1 a , 1 b , and 1 c are a flow chart ( 10 ) illustrating a process for verifying migration of metadata. The following set of steps is conducted for each file and folder that has been migrated. If any of the comparisons fail, this is an indication that the security information related to the data may have been compromised. The file size of the source file is compared to the file size of the destination file ( 12 ). A test is then conducted to determine if the source and destination file sizes match ( 14 ). If the response to the test at step ( 14 ) is negative, a flag is set to indicate that the file sizes do not match ( 16 ). Following a positive response to the test at step ( 14 ) or setting of the flag at step ( 16 ), a comparison is conducted of the file attributes of the source file with the file attributes of the destination file ( 18 ). Thereafter, a test is conducted to determine if the file attributes compared at step ( 18 ) match ( 20 ). If the response to the test at step ( 20 ) is negative, a flag is set to indicate that the attributes of the source and destination files do not match ( 22 ). A positive response to the test at step ( 20 ) or following setting of the flag at step ( 22 ) will result in a subsequent test to compare the file creation time for the source file with the file creation time for the destination file ( 24 ). Following the comparison at step ( 24 ), a test is conducted to determine if the file creation times compared at step ( 24 ) match ( 26 ). If the response to the test at step ( 26 ) is negative, a flag is set to indicate that the file creation times of the source and destination files do not match ( 28 ). Similarly, following a positive response to the test at step ( 26 ) or setting of the flag at step ( 28 ), a comparison is conducted of the last write time of the file at both the source and destination locations ( 30 ). Thereafter, a test is conducted to determine if the write times compared at step ( 30 ) match ( 32 ). A negative response to the test at step ( 32 ) will result in setting a flag ( 34 ), and a positive response to the test at step ( 32 ) will result in a comparison of the owner security descriptor for the source file with the owner security descriptor for the destination file ( 36 ). The security descriptor is a description of the security associated with the file and is commonly used in file storage to indicate ownership rights of the file and permission rights for access to the file. More specifically, the security descriptor identifies the file objects owner and primary group, and may also contain an access control list (DACL) that is controlled by the owner of an object and that specifies access particular users or groups can have to the object. Following the comparison at step ( 36 ), a test is conducted to determine if the owner security descriptors compared at step ( 36 ) match ( 38 ). A negative response to the test at step ( 38 ) will result in setting a flag to indicate that the owner security descriptors of the source and destination files do not match ( 40 ). Alternatively, a positive response to the test at step ( 38 ) or setting of the flag at step ( 40 ) will result in a subsequent comparison of group security descriptors for the file at both the source and destination filesystems ( 42 ). The comparison at step ( 42 ) is followed by a test to determine if the group security descriptors match ( 44 ). A negative response to the test at step ( 44 ) will result in setting a flag indicating the mismatch ( 46 ). Following the setting of the flag at step ( 46 ) or a positive response to the test at step ( 44 ), a comparison is conducted of the number of access control entries (ACEs) of the source file with the ACEs of the destination file ( 48 ). Each ACE specifies a set of access rights and contains a security identifier (SID) that identifies a trustee for whom the rights are allowed, denied, or audited. A trustee can be a user account, a group account, or a logon session. Thereafter, a test is conducted to determine if the quantity of ACEs of the file at the source and destination filesystems match ( 50 ). If the quantity of ACEs compared at step ( 50 ) does not match, a flag is set to indicate the mismatch ( 52 ). However, if the quantity of ACEs compared at step ( 50 ) match or following setting of the flag at step ( 52 ), a comparison of each ACE at both the source and destination files is conducted ( 54 ). Thereafter, a test is conducted to determine if each ACE compared at step ( 54 ) matches ( 56 ). A negative response to the test at step ( 56 ) will result in setting a flag for each ACE that did not match ( 58 ). Following setting of the flag (s) at step ( 58 ) or a positive response to the test at step ( 54 ), a final test of the verification is conducted to determine if any flags have been set in the verification process ( 60 ). A positive response to the test at step ( 60 ) will in compilation of a list of all flags set during the comparison processes and forwarding of the compiled list to an operator ( 64 ). Alternatively, if the response to the test at step ( 60 ) is negative, this is an indication that the metadata of the source and destination filesystems match ( 62 ). Accordingly, the above outlined process is conducted for each file and folder that is migrated from a source filesystem to a destination filesystem to ensure that the migration was successful.
As shown in FIGS. 1 a , 1 b , and 1 c , one part of the metadata verification process is to determine creation time of the file at both the source and destination locations. FIG. 2 is a flow chart ( 100 ) illustrating the process for comparing time attributes associated with copies of the file at both the source and destination locations. To compare the creation time for the files, the time resolution for the creation of the file at the source location is determined ( 102 ). Time resolution is the granularity of the time variable associated with creation of the file. Following the determination at step ( 102 ), the time resolution for the creation of the file at the destination location is determined ( 104 ). The details of the logic associated with steps ( 102 ) and ( 104 ) are shown in FIG. 3 . Upon completion of the determinations at steps ( 102 ) and ( 104 ) the file creation time of the file for the source location is compared to the file creation time of the file for the destination location ( 106 ). The details of the comparison conducted at step ( 106 ) are shown in FIGS. 4 a and 4 b . Following the comparison at step ( 106 ), a test is conducted to determine if the file creation time for the file at the source and destination locations compared at step ( 106 ) match ( 108 ). If the comparison at step ( 108 ) fails, a flag is set to indicate the failure ( 110 ). Following setting of the flag at step ( 110 ) or if the test at step ( 108 ) does not fail, a subsequent determination is conducted for the time resolution for the last write time of the file at the source location ( 112 ), followed by a determination for the time resolution for the last write time of the file at the destination location ( 114 ). The details of the logic associated with steps ( 112 ) and ( 114 ) are shown in FIG. 5 . Following the determination at steps ( 112 ) and ( 114 ), a comparison is conducted of the last write time of the file for the source location with the last write time of the file for the destination location ( 116 ). The details of the logic associated with the comparison at step ( 116 ) is shown in FIGS. 6 a and 6 b . Following the comparison at step ( 116 ), a test is conducted to determine if the last write time of the file at the source location matches with the last write time of the file at the destination location ( 118 ). A negative response to the test at step ( 118 ) will result in setting a flag to indicate the false return of the comparison ( 120 ), i.e. a last write time mismatch. Following step ( 120 ) or a positive response to the test at step ( 118 ), an inquiry ( 122 ) is conducted to determine if a flag has been set in relation to the file creation time comparison at step ( 110 ) or in relation to the last write time comparison at step ( 120 ). If the response to the inquiry at step ( 122 ) is positive, the flags set at steps ( 110 ) and ( 120 ) are compiled and forwarded to an operator. Alternatively, a negative response to the test at step ( 122 ) is an indication that the file creation time and last write time match. Accordingly, the comparison of the creation time of the source and destination files requires determinations and comparisons associated with the resolution of the file creation time for each of the locations.
FIGS. 3 a and 3 b are a flow chart ( 150 ) illustrating the process for determining the time resolution for creation time in a filesystem. A temporary file is created on the filesystem whose resolution is being determined ( 152 ). A first local variable is initialized to “UP” ( 154 ), and a second local variable is initialized to “1” ( 156 ). The Microsoft® Windows® application programming interface (API) is used to call the operating system to find information on the temporary file created at step ( 152 ) and to retrieve the associated file creation time of the temporary file ( 158 ). The data returned at step ( 158 ) is stored as variable time 1 ( 160 ). Thereafter, a test is conducted to determine if the value of the variable time 1 is zero ( 162 ). A positive response to the test at step ( 162 ) is an indication that the filesystem does not store the file creation time, and the resolution of the file creation time for the filesystem is set to zero ( 164 ). However, a negative response to the test at step ( 162 ) results in setting a new time variable, time 2 , and setting this variable to the sum of time 1 and the second local variable ( 166 ). Thereafter, a call to the operating system is conducted to modify the creation time of the temporary file to time 2 ( 168 ), followed be another call to the operating system to retrieve the file creation time of the temporary file ( 170 ). The retrieved file creation time is stored as variable time 2 ( 172 ). A test is then conducted to determine if the value of time 2 is greater than the value of time 1 ( 174 ). If the response to the test at step ( 174 ) is negative, the first local variable is set to “DOWN” and the second local variable is incremented by a value of one ( 176 ), followed by a return to step ( 166 ). However, a positive response to the test at step ( 174 ) will result in setting the resolution of the filesystem as the difference between time 2 and time 1 ( 178 ). The value returned at step ( 178 ) is returned to the logic at steps ( 102 ) and ( 104 ) of FIG. 2 to compare the time resolution of the file at a specified filesystem.
FIGS. 4 a and 4 b are a flow chart ( 200 ) illustrating the details of the process for comparing the file creation time of a specified file at the source and destination locations. A first resolution variable is set as the resolution of the file when the file was created at the source location ( 202 ), and a second resolution variable is set as the resolution of the file when the file was created at the destination location ( 204 ). In addition, a first time variable is set as the creation time of the file at the source location ( 206 ), and a second time variable is set as the creation time of the file at the destination location ( 208 ). Thereafter, a test is conducted to determine if the first time variable or the second time variable is set to zero ( 210 ). A positive response to the test at step ( 210 ) is an indication that the file creation time of the file at the source and destination locations cannot be compared ( 212 ). However, a negative response to the test at step ( 210 ) is an indication that the file creation time of the two locations can be compared. A subsequent test is conducted to determine if the second resolution variable is less than or equal to the first resolution variable ( 214 ). A positive response to the test at step ( 214 ) will result in a subsequent test to determine if the first time variable is equal to the second time variable ( 216 ). A positive response to the test at step ( 216 ) is an indication that the file creation time of the designated files at the source and destination locations match ( 218 ). However, a negative response to the test at step ( 216 ) is an indication that the file creation time of the designated files at the source and destination locations do not match ( 220 ).
Similarly, a negative response to the test at step ( 214 ) will result in a subsequent test to determine if the first local variable used in determining the resolution of the creation of the file in the destination location set in FIGS. 3 a and 3 b is set to “UP” ( 222 ). A positive response to the test at step ( 222 ) is an indication that the time resolution of designated files at both the source and destination locations match. Thereafter, a subsequent test is conducted to determine if the first time variable set at step ( 206 ) falls within the following range ( 224 ): the upper limit of the second time variable set at step ( 208 ), and the lower limit of the difference between the second time variable set at step ( 208 ) and the sum of the second resolution variable set at step ( 204 ) incremented by an integer of one. If the response to the test at step ( 224 ) is positive, this is an indication that the file creation time of the designated files at the source and destination locations match ( 218 ). However, if the response to the test at step ( 224 ) is negative, this is an indication that the file creation time of the source and destination locations do not match ( 220 ). Finally, a negative response to the test at step ( 222 ) will result in a subsequent test to determine if the first time variable set at step ( 206 ) falls within the following range ( 226 ): the upper limit of the second time variable set at step ( 208 ), and the lower limit of the difference between the second time variable set at step ( 208 ) and the second time variable decreased by an integer of one. A positive response to the test at step ( 226 ) is an indication that the file creation time of the designated files at the source and destination locations match ( 218 ), and a negative response to the test at step ( 226 ) is an indication that the file creation time of the designated files at the source and destination locations do not match ( 220 ). Accordingly, the process of determining a match of file creation times on different locations includes an evaluation of the resolution used to track time.
FIGS. 5 a and 5 b are a flow chart ( 250 ) illustrating the details of determining the time resolution for the last write time in a filesystem. The process demonstrated in this figure is similar to that shown in FIG. 3 . A temporary file is created on the filesystem whose resolution is being determined ( 252 ). A first local variable is initialized to “UP” ( 254 ), and a second local variable is initialized to “1” ( 256 ). The Microsoft® Windows® application programming interface (API) is used to call the operating system to find information on the temporary file created at step ( 252 ) and to retrieve the associated last write time of the temporary file ( 258 ). The data returned at step ( 258 ), i.e. the last write time, is stored as variable time 1 ( 260 ). Thereafter, a test is conducted to determine if the value of the variable time 1 is zero ( 262 ). A positive response to the test at step ( 262 ) is an indication that the filesystem does not store the last write time of the file, and the resolution of the last write time for the filesystem is set to zero ( 264 ). However, a negative response to the test at step ( 262 ) results in setting a new variable time 2 and setting this variable to the sum of time 1 and the second local variable ( 266 ). Thereafter, a call to the operating system is conducted to modify the last write time of the temporary file created at step ( 252 ) to time 2 ( 268 ), followed by a subsequent call to the operating system again to obtain information about the temporary file and to retrieve its new value of last write time ( 270 ). The data returned in step ( 270 ) is stored as variable time 2 ( 272 ). A test is then conducted to determine if the value of time 2 is greater than the value of time 1 ( 274 ). If the response to the test at step ( 274 ) is negative, the first local variable is set to “DOWN” and the second local variable is incremented by a value of one ( 276 ), followed by a return to step ( 266 ). However, a positive response to the test at step ( 274 ) will result in setting the resolution of the last write time of the filesystem as the difference between time 2 and time 1 , ( 278 ). The value returned at step ( 278 ) is returned to the logic at steps ( 112 ) and ( 114 ) of FIG. 2 to provide the resolution of the last write time of the filesystem.
FIGS. 6 a and 6 b are a flow chart ( 300 ) demonstrating a process for comparing the last write time of a file at two locations. A first variable is set as the resolution of the last write time of a source file at a source location ( 302 ), and a second variable is set as the resolution of the last write time of a destination file at a destination location ( 304 ). In addition, a first time variable is set as the last write time of the source file at the source location ( 306 ), and a second time variable is set as the last write time of the destination file at a destination location ( 308 ). A test is then conducted to determine if the first time variable set at step ( 306 ) or the second time variable set at step ( 308 ) has a value of zero ( 310 ). If the response to the test at step ( 310 ) is positive, this is an indication that the last write time of source and destination files cannot be compared ( 312 ). However, a negative response to the test at step ( 310 ) is an indication that the comparison of last write times can be commenced. Another test ( 314 ) is conducted to determine if the second resolution variable set at step ( 304 ) is less than or equal to the first resolution variable set at step ( 302 ). If the response to the test at step ( 314 ) is positive, a subsequent test ( 316 ) is conducted to determine if the first time variable set at step ( 306 ) is equal to the second time variable set at step ( 308 ). A negative response to the test at step ( 316 ) is an indication that the last write time of the file at the source and destination locations do not match ( 320 ). Similarly, a positive response to the test at step ( 316 ) is an indication that the last write time of the file at both the source and destination locations match ( 318 ). However, if the response to the test at step ( 314 ) is negative, a subsequent test is conducted to determine if the first local variable used in determining the resolution of the last write time of the file in destination location set in FIGS. 5 a and 5 b is set to “UP” ( 322 ). A positive response to the test at step ( 322 ) will result in a subsequent test to determine if the first time variable set at step ( 306 ) falls within a range defined by an upper limit of the second time variable set at step ( 308 ) and a lower limit of the second time variable set at step ( 308 ) less the second resolution variable set at step ( 304 ) incremented by an integer of one ( 324 ). A positive response to the test at step ( 324 ) is an indication that the last write time of the file at the two locations matches ( 320 ). Alternatively, a negative response to the test at step ( 324 ) is an indication that the last write time of the file at the two locations does not match ( 318 ). Finally, if the response to the test at step ( 322 ) is negative, a final test ( 326 ) is conducted to determine if the first time variable set at step ( 306 ) falls within a range defined by an upper limit of the second time variable set at step ( 308 ) and a lower limit of the sum second time variable set at step ( 308 ) and the second resolution variable set at step ( 304 ) less an integer of one. A positive response to the test at step ( 326 ) is an indication that the last write time of the file at the two locations match ( 320 ), and a negative response to the test at step ( 326 ) is an indication that the last write time of the file at the two locations do not match ( 318 ). Accordingly, the results of the last write time comparison is forwarded to the test conducted at step ( 116 ) of FIG. 2 .
Advantages Over The Prior Art
The metadata verification process is automated for all filesystem transfer of files and/or folders. A correct transfer of the migrated files and/or folders is an indication that the transfer is complete and security of the files and/or folders has not been compromised in the transfer. In the event the integrity of the metadata transfer has been compromised, a compilation of flags associated with each error is forwarded to the operator to indicate a source of error associated with the data migration. Accordingly, the automated tool functions to detect differences in metadata in two copies of a file set, and in the event a difference is detected that associated error is communicated to the operator.
Alternative Embodiments
It will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. In particular, the metadata verification tool may be modified to compare additional metadata fields, or only select metadata fields. Accordingly, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
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A method and system for maintaining integrity of metadata associated with a migrated file. Following migration of data from a source filesystem to a destination filesystem, a tool is automatically invoked to detect if there are any differences in metadata associated with the files and/or folders at each location. Each select field of the metadata at the source filesystem is reviewed to ensure that it matches with the equivalent field at the destination filesystem. In the event at least one of the reviewed metadata fields does not match, an error is generated and forwarded to an operator.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/199,724, “Web-based Coordination and Payments,” filed Nov. 18, 2008. The subject matter of all of the foregoing is incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to the coordination of volunteers using web-based sign-up sheets.
[0004] 2. Description of the Related Art
[0005] Coordinating a group for an activity can be a complicated task with many moving parts. The organizer of the activity may have to coordinate many people who are volunteering for a large number of specific tasks. The tasks may take place at different times, in shifts, at different locations. Some tasks may require specialized skill. The organizer may also have to coordinate people who are bringing items to the activity. As part of this coordination, the organizer may want to pre-assign certain volunteers to certain tasks. The organizer typically will also want to exert some control over volunteers changing their commitments. Many activities also involve some sort of payment, which adds an additional dimension of tracking and handling money.
[0006] This coordination task can be even more difficult for informal, intermittent or transient groups of moderate to large size. Such groups may exist for only one activity or a small number of activities. Since they are transient, it does not make sense to use a complicated, powerful coordination tool. By the time the volunteers learn how to use such a tool, the group's usefulness will be over, which means that the tool will not be used during the useful life of the group. On the other hand, since the group is moderate or large, simple approaches such as sending emails to everyone can be inefficient at best and completely bothersome and ineffective at worst.
[0007] Furthermore, there are a large number of activities and groups that fall into this category. For example, the “social director” of a company department may be organizing a potluck dinner for the department, and must coordinate who is bringing what in addition to who is coming. Or a PTA committee chair may be organizing a carnival fundraiser for a local school, and must coordinate who is manning which carnival booths as well as who is bringing supplies, setting up and cleaning up. Or a community volunteer may be organizing a local food drive, and must coordinate who will cover which neighborhoods at which times. Or a soccer coach may be organizing practices and games, and must coordinate who will bring snacks, sports equipment and serve as referees, set up and clean up.
[0008] Organizers of these activities typically would like to perform several tasks. It is often beneficial to create and manage a common auto-updating web page for volunteers for an activity. Organizers often desire to intelligently manage sign-ups with the changes that occur around the activity and to communicate them effectively to impacted volunteers. In some cases, organizers desire to pre-assign volunteers if needed and keep track of them as if they had signed up on their own (e.g., provide updates, reminders and thank you notes).
[0009] In addition, from the volunteer's perspective, the ability to volunteer and commit to certain tasks in an activity should be simple and straightforward. Volunteers may also desire to contribute in a coordinated way to the activity and to participate in the online coordination effort for the activity. If payments are required, it would be beneficial to enable volunteers to make corresponding payments (e.g., for dues and donations) at the same time and on the same web site as they sign-up for the activity. To simplify sign-ups, volunteers preferably should be able to commit to tasks without having to first register for a service or otherwise provide significant additional information.
[0010] Existing web-based sites and products generally are not satisfactory for this type of coordination. Some current products provide one way announcement of events with RSVPs from invitees (Evite). However, these products typically do not provide enough power or flexibility to allow the organizer to effectively coordinate the group effort.
[0011] Other group solutions, such as Y!Groups and emails work well only when communicating one way (i.e., broadcasting information from group moderator/leader to participants). However, because of the back-and-forth nature of group coordination, these same products fail to accommodate user needs both for the organizer as well as the participants of sign-up sheets. The larger the group, the more cumbersome and unwieldy the one-way products become. Multiple sets of emails, questions and confirmations are often necessary, with the communications often broadcast to an overly large group. For example, in a group size of 20 (average elementary school classroom size) when using Y!Groups, for every one useful Y!Group message, each member typically receives many non-useful messages as part of the coordination effort.
[0012] As a result of these inherent limitations, it can be difficult to keep track of who has committed to do which tasks and who to contact if there is a change in tasks or schedule. It can even be difficult for volunteer candidates to determine which tasks are committed and which are available. Furthermore, if there is a payment element involved, the organizer often goes through the additional trouble of setting up a separate account on a separate site for the payment to be made and participants are asked to sign-up for activities on one product and then do the payments on yet a different product. As a result, many payments are currently done in cash or checks and therefore add another layer of cumbersomeness.
[0013] Thus, there is a need for approaches that better facilitate the coordination of medium-to-large groups of volunteers and/or complex projects with multiple layers of volunteers involved.
SUMMARY OF THE INVENTION
[0014] In one aspect, the present invention overcomes the limitations of the prior art by allowing organizers to create a light-weight, easy to use, commonly accessible, sign-up sheet that can be sent to volunteers and/or participants on email or other social media vehicles. The sign-up sheet preferably has some or all of the following features. In some cases, the sign-up sheet auto-updates and keeps everyone informed. It preferably aids the organizer (and volunteers) in dealing with changes to the sign-up sheet. In one aspect, organizers can pre-assign volunteers to tasks. The sign-up sheet preferably helps all parties involved to keep an accurate and current record of commitments to tasks, including commitments of time, items and payments, without the need to resort to multiple unnecessary broadcast emails. The platform preferably allows the organizer to send automated reminder emails to volunteers at the right time with the correct information. Preferably, it also allows for customized thank you notes.
[0015] In one approach according to the invention, a software platform enables group sign-up sheets on the Internet. As example, a sign-up sheet could be for organizing snack duty for a soccer team (different families bring snacks on different weeks), or organizing carpools (to drive to and from different locations on different days and different times) or creating a teacher's wish list for parents to donate money or purchase items from the list.
[0016] In one design, easy-to-use templates and widgets allow a user in a limited number of simple steps to create a sign-up sheet and email a URL for the sign-up sheet to volunteer candidates. The volunteer candidates receive the emails in their usual email box. By clicking on the URL, they are able to see which tasks on the sign-up sheet are available and which are taken (i.e., already committed). The information reflects the current status of the sign-up sheet, avoiding problems such as double-booking and accommodating modifications by the organizer (change management). In cases where changes are made to the sign-up sheet, communications are sent to the impacted volunteers, without bothering the non-impacted volunteers. Automatic reminders and calendar Task Notes can also be generated by the platform. In addition, the platform can provide pre-filled templates for specific occasions that an organizer could use as the starting point of building their sign-up sheets.
[0017] Many times during the sign-up process, volunteers are also asked to make payments or donate money, for example towards the purchase of a gift, to pay for uniforms or buy tickets for the event where they are volunteering. In one aspect of the invention, the software platform includes a group coordination product with payment capabilities enabling users to coordinate online while also making the necessary payments.
[0018] Other aspects of the invention include methods corresponding to the devices and systems described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention has other advantages and features which will be more readily apparent from the following detailed description of the invention and the appended claims, when taken in conjunction with the accompanying drawings, in which:
[0020] FIG. 1 is a screenshot that shows a home page for a service according to the invention.
[0021] FIG. 2A is a screenshot that shows a first step in creating a sign-up sheet.
[0022] FIG. 2B is a screenshot that shows a completed sign-up sheet.
[0023] FIG. 2C is a screenshot that shows a gallery of sign-up sheets.
[0024] FIG. 2D is a screenshot that shows a sign-up sheet selected from the gallery.
[0025] FIG. 3A is a screenshot that shows the ability to edit a sign-up sheet.
[0026] FIG. 3B is a screenshot of a dialog box for editing volunteers.
[0027] FIG. 4 is a screenshot that shows an ability to assign payments to the sign-up sheet.
[0028] FIG. 5 is a screenshot that shows Amazon' s interface to Jooners.
[0029] FIG. 6 is a screenshot that shows completing the sign-up sheet creation process.
[0030] FIG. 7A is a screenshot that shows an email generated and sent from Jooners.
[0031] FIG. 7B is a screenshot that shows an email containing the URL of the sign-up sheet.
[0032] FIG. 8 is a screenshot of the sign-up sheet displayed to the volunteer candidate.
[0033] FIG. 9 is a screenshot that shows a payments page.
[0034] FIG. 10 is a screenshot that shows confirmation of successful sign-up and payment to the volunteer.
[0035] FIG. 11 is a screenshot that shows the results of modification to an existing sign-up sheet.
[0036] FIG. 12 is a screenshot that shows reminders.
[0037] FIG. 13A is a screenshot that shows thank you notes.
[0038] FIG. 13B is a screenshot that shows thank you notes as received by volunteers.
[0039] The figures depict embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The figures and the following description relate to preferred embodiments by way of illustration only. It should be noted that from the following discussion, alternative embodiments of the structures and methods disclosed herein will be readily recognized as viable alternatives that may be employed without departing from the principles of what is claimed.
[0041] FIGS. 1-13 illustrate an example according to the invention. FIG. 1 is a screen shot of the home page of an example located at web site www.jooners.com. From this home page, the organizer can create new sign-up sheets, including accessing a gallery of pre-existing sign-up sheets (Popular Planners tab 120 ). He can also see all the different sign-up sheets that have been created, saved or sent, by accessing the My Jooners box 130 . The organizer's own activities, time or item commitments are placed on his calendar 140 .
[0042] Clicking on Coordinate Volunteers 110 brings the organizer to a template for coordinating volunteers (i.e., a type of sign-up sheet). Step 1 of this template is shown in FIG. 2A . The organizer fills out this screen. An example of a filled out screen is shown in FIG. 2B . The organizer clicks the Next button to go to Step 2 , as shown in FIG. 3 .
[0043] Alternatively, the organizer can go to the Popular Planners tab 120 , which contains a gallery of templates for sign-up sheets, depending on the nature of the activity. FIG. 2C is a screenshot that shows a gallery of sign-up sheets, organized by category 250 . FIG. 2D is a screenshot that shows a sign-up sheet selected from the gallery, in this example it is a sign-up sheet for a block party. The organizer can then use the template to define his sign-up sheet.
[0044] The templates are used by the organizer to define his sign-up sheet. To facilitate this, the templates preferably are displayed in a manner that looks like a sign-up sheet. The organizer can then change the different aspects of the sign-up sheet. For example, the organizer can define different tasks for the activity. The tasks preferably can be defined using at least two different variable parameters. Examples include defining tasks by combinations of time, location, job function and required items.
[0045] In FIG. 3A , the organizer verifies the information entered previously and enters verbal commitments by pre-assigning tasks to specific volunteers. The organizer can save the sign-up sheet as a draft and return to it later. Pre-assignment of volunteers is included as part of the sign-up sheet creation process, in this example. The system is designed such that even these pre-assigned volunteers receive reminders and thank you notes and are dealt with as if they had signed up themselves. FIG. 3B shows a dialog box that shows the ability and control of the organizer to pre-assign and/or remove volunteers.
[0046] Clicking Next in FIG. 3A brings the organizer to Step 3 , as shown in FIG. 4 . Step 3 , labeled PAYMENTS, gives organizers the ability to include payments with the sign-up sheet. In this example, the organizer can specify the suggested amount of the payment.
[0047] Once done specifying the payment parameters (amount, etc.), in this example, the organizer is taken to a separate payment platform provider such as Amazon where the setup and linking of the Payment services of Amazon is linked to this Jooners account/user. See FIG. 5 .
[0048] Once done with the set up of the Payment services, the organizer is brought back to Jooners and the flow of setting up the template with payments is completed. Note that for accounting on who among the volunteers/participants has or has not paid, the user is taken to Amazon (in this implementation).
[0049] The last step in this example (Step 4 ), as shown in FIG. 6 , facilitates the sending of the sign-up sheet (with payments capability) to volunteer candidates. In this example, the software platform auto generates an email, which the organizer can send to volunteer candidates. More importantly, the software platform creates a URL 610 for the sign-up sheet. The URL is presented to the organizer in a form that can be electronically copied into other communications. Thus, the organizer can send invitations using many other communications forms, and not only the forms generated by the software platform. The organizer can also send out invitations at different times. For example, the organizer might send out a first wave of invitations, wait to see how sign-ups progress, and then send out a second wave of invitations. The volunteers can also pass around the sign-up sheet simply by passing around the URL. In this example, the Jooners system auto generates an email invite, but the organizer can decide to use the URL generated by Jooners in a personal email to volunteer candidates (sent by the organizer not Jooners system), or various other social media vehicles such as blogs, newsletters, twitter messages etc.
[0050] On the participant side, in FIG. 7A , the email auto-generated by the Jooners system is received by the participant in his/her normal email box. The organizer has customized the email message received by the participants. The participant clicks on a link 710 in the body of the email message and is directed to the sign-up sheet shown in FIG. 8 , where the participant is able to sign-up for items in the list provided by the organizer, without needing to register for Jooners or have an account on Jooners (in this example).
[0051] FIG. 7B shows an example where the organizer independently sends out an email containing the URL 720 in the body of the email. The recipient can click on the URL to be directed to the sign-up sheet, as shown in FIG. 8 .
[0052] From FIG. 8 , the volunteer can see the entire sign-up sheet, including who else has already committed to which other tasks. This allows the volunteer to determine which tasks are still available. The sign-up sheet is automatically updated according to the volunteer's responses.
[0053] Clicking on NEXT in FIG. 8 navigates to the payments page, as shown in FIG. 9 . In this example, the participant chooses the quantity of the payment and gets an estimated total. By clicking on PAY, the participant is taken to the payment platform such as Amazon to verify his/her credentials and make the payment. If payment is made, the participant is brought back to Jooners, for example the screen shot shown in FIG. 10 . The payments page can be set up for many types of payments, for example paying for dues, tickets, or gift contributions.
[0054] The organizer can click on the item in his/her MY JOONERS box to see the confirmation that payment has been made and a list of tasks for which volunteers have committed. For the organizer, the accounting on who has paid can be shown on a screen. Also, the organizer can see what items have been committed to and go to the Amazon/Payment platform provider to see the list of payors. For volunteers and participants, they can click on the sign-up sheet URL to see who has committed to which tasks.
[0055] In one approach, integrity of the sign-up sheet is maintained by controlling authority to make changes to the volunteer commitments. One rule is to allow only the organizer to make changes. Thus, if a volunteer commits to a task and then later changes his mind, the volunteer must have the organizer change the commitment on the sign-up sheet. A different rule would be to allow both the organizer and the volunteer to change a volunteer's commitment. Authority may also vary over time, for example with more changes allowed when there is still time before the activity, and fewer changes allowed as the activity draws near.
[0056] In the current example, the organizer can edit an existing sign-up sheet at either Step 1 or Step 2 . If an organizer makes changes to an existing sign-up sheet, it would be useful to notify any affected volunteers, for example as shown in FIG. 11 .
[0057] Other groups can also be useful. For example, the organizer may send his original email to a wide group of volunteer candidates. However, some later communications may go to only those volunteers who have signed up on the sign-up sheet, or to only those who have signed up for certain tasks.
[0058] For example, three days before the activity date, a reminder is automatically sent to all volunteers on the sign-up sheet, listing the date, item and timing of their commitment. FIG. 12 is an example of this. If changes were made throughout the process, they are reflected in these reminders. The ability to modify how soon or how many times a reminder goes out is defined by the organizer in this example. The ability to turn off reminders is in the hands of the volunteers, in this example.
[0059] The organizer, at the conclusion of the activity, may decide to thank volunteers via an email. Jooners provides the ability to quickly create customized thank you notes that are sent to participating volunteers. For example, see FIGS. 13A and 13B .
[0060] The sign-up sheet examples shown above are especially useful for mid-sized, non-persistent groups. For very small groups, coordination can be done by emails or phone calls. For very large groups, more sophisticated software will have additional benefits. However, tools such as Jooners is especially useful for mid-sized groups, for example between 10 and 100 volunteer candidates, or even up to between 10 and 1000 volunteer candidates. It is also well-suited to transient groups—groups which come together for a temporary period of time. For example, permanently established groups that take on repetitive activities can develop other types of sign-up sheets due to their repeated nature.
[0061] Although the detailed description contains many specifics, these should not be construed as limiting the scope of the invention but merely as illustrating different examples and aspects of the invention. It should be appreciated that the scope of the invention includes other embodiments not discussed in detail above. Various other modifications, changes and variations which will be apparent to those skilled in the art may be made in the arrangement, operation and details of the method and apparatus of the present invention disclosed herein without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, the scope of the invention should be determined by the appended claims and their legal equivalents.
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A light-weight, easy to use, commonly accessible, sign-up sheet that can be sent to volunteers and/or participants on email or social media vehicles. The sign-up sheet preferably has some or all of the following features. In some cases, the sign-up sheet auto-updates and keeps everyone informed. It preferably aids the organizer (and volunteers) in dealing with changes to the sign-up sheet. In one aspect, organizers can pre-assign volunteers to tasks. The sign-up sheet, preferably at all times, helps all parties involved to keep an accurate and current record of commitments to tasks, including commitments of time, items and payments, without the need to resort to multiple unnecessary broadcast emails. The platform preferably allows the organizer to send automated reminder emails to volunteers at the right time with the correct information.
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The present application is based on Japanese patent application No. 2010-131109 filed on Jun. 8, 2010, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a key interlock device that is attached to a steering lock device for a vehicle.
2. Description of the Related Art
Steering lock devices have been popularized that are equipped with a key interlock device to restrain a steering key (i.e., ignition key) from being turned form an “ACC” position to “LOCK” position when the vehicle is driven. The key interlock device uses an attraction type solenoid that is operable to attract a plunger when it is excited (e.g., JP-A-2000-229557).
The attraction type solenoid operates to attract the plunger when a drive current is fed (i.e., the solenoid is excited or energized), so that a problem arises that the power consumption increases. Therefore, in recent years, the key interlock device is desired to use a retention type solenoid that can relatively save the power consumption.
SUMMARY OF THE INVENTION
Although the retention type solenoid can hold the plunger at the excited state, it cannot have the plunger actively operate. Thus, when the retention type solenoid is used for the key interlock device, a lock mechanism needs to be constructed adding a new reinforcement member such as a link. Therefore, it is necessary to prevent an increase in the manufacturing cost due to increased parts, complicated installation process and the like.
Accordingly, it is an object of the invention to provide a key interlock device that can prevent an increase in the manufacturing cost when the retention type solenoid is used.
(1) According to one embodiment of the invention, a key interlock device comprises:
a solenoid that holds a plunger when the solenoid is excited; and
a link member that comprises a shaft around which the link member is rotatable, and engages with the plunger so as to transmit a restraining force opposing an operation force of a key when the solenoid is excited,
wherein the shaft of the link member is disposed on a virtual line extending from a line of force of the operation force of the key.
In the above embodiment (1) of the invention, the following modifications and changes can be made.
(i) The link member further comprises a linear arm part along the line of force of the operation force of the key.
(ii) The link member further comprises a resin.
(2) According to another embodiment of the invention, a key interlock device comprises:
a solenoid that holds a plunger when the solenoid is excited; and
a link member that comprises a shaft around which the link member is rotatable and engages with the plunger so as to transmit a restraining force opposing an operation force of a key when the solenoid is excited,
wherein the shaft of the link member is disposed on a virtual line extending from a line of force of the operation force of the key, and
wherein the key interlock device further comprises an engaging part through which the key interlock device is attached to a body of a steering lock device and which is disposed behind the shaft to which the operation force of the key applies.
In the above embodiment (2) of the invention, the following modifications and changes can be made.
(iii) The link member further comprises a linear arm part along the line of force of the operation force of the key.
(iv) The link member further comprises a resin.
(v) The engaging part is disposed at one end of the key interlock device and is adapted to be inserted into an opening of the body of the steering lock device, and the key interlock device is fixed to the body at an other end thereof.
(vi) The engaging part is disposed at one end of the key interlock device in a direction of turning back the key from an ACC position to a LOCK position thereof.
(vii) The arm part comprises a pressure receiving surface at an end, and the pressure receiving surface contacts an action surface to which the operation force of the key applies.
(viii) The pressure receiving surface contacts the action surface to restrain the key from being turned back from an ACC position to a LOCK position thereof when the solenoid is excited.
Points of the Invention
According to one embodiment of the invention, a key interlock device (or interlock unit) is constructed such that a rotation shaft part for rotatably supporting a link and a pin penetrating through the rotation shaft part are disposed on a virtual line extending from a line of force of a rotation force generated in the tangential direction of a cam shaft operated by a key (regular or authentic key). Since the rotation force from the cam shaft is received at the rotation shaft part and the pin, the burden of a load to the link can be reduced. In addition, an arm part of the link is formed to extend linearly from the rotation shaft part as a center, so that only a compression load component acts on the arm part without a bending stress component. The link mechanism thus constructed is used as a reinforcement part of a retention solenoid, so that the link may be formed of a resin such as PBT having high resistance to a compression load instead of metals. Thus, the manufacturing cost of the key interlock device can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments according to the invention will be explained below referring to the drawings, wherein:
FIG. 1A is a side view schematically showing a steering lock device using a key interlock device according to one embodiment of the present invention, in which a part of a bracket for fixing a steering column thereof is shown in a partially broken state;
FIG. 1B is a bottom view schematically showing the steering lock device shown in FIG. 1A ;
FIG. 2 is a longitudinal cross-sectional view schematically showing an inner structure of the steering lock device using the key interlock device according to one embodiment of the present invention;
FIG. 3 is a cross-sectional view schematically showing parts of a lock bar and the steering column in the steering lock device using the key interlock device according to one embodiment of the present invention;
FIG. 4 is an exploded perspective view schematically showing an internal constitution of an interlock unit as the key interlock device according to one embodiment of the present invention;
FIG. 5 is a perspective view schematically showing an installation method of an interlock unit as the key interlock device according to one embodiment of the present invention in the steering lock device;
FIG. 6A is a front view schematically showing an inner structure of the interlock unit as the key interlock device according to one embodiment of the present invention, in which the interlock unit is in an interlock state; and
FIG. 6B is a front view schematically showing an inner structure of the interlock unit as the key interlock device according to one embodiment of the present invention, in which the interlock unit is in a state that the interlock state is released.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will be detailed below with reference to drawings. First, a steering lock device 1 will be explained, that includes an interlock unit 30 as an interlock key device according to the present invention. Here, FIG. 1A is a side view schematically showing the steering lock device 1 using the interlock key device according to one embodiment of the present invention, in which a part of a bracket 102 for fixing a steering column 80 thereof is shown in a partially broken state. In addition, FIG. 1B is a bottom view schematically showing the steering lock device 1 shown in FIG. 1A . The steering lock device 1 is configured so as to include a key part 10 , a steering lock part 20 , the interlock unit 30 and an ignition switch unit 40 .
FIG. 2 is a longitudinal cross-sectional view schematically showing an inner structure of the steering lock device 1 . A case 101 of the steering lock device 1 is integrally formed of a metal such as zinc die-cast. A key cylinder 110 that has a cylinder 111 and a rotor rotatably housed in the cylinder 111 is mounted in the case 10 by insertion thereinto. A key hole 112 a into which a key K is inserted is formed in the rotor 112 of the key cylinder 110 so as to extend toward the inside in the axis direction.
In addition, a plurality of tumblers 113 , 113 , . . . having an elongate shape in the diameter direction (vertical direction) of the rotor 112 are housed in the rotor 112 along the longitudinal direction thereof in a movable state. Each end portion of tumblers 113 , 113 , . . . projects from an outer periphery of the rotor 112 so as to engages with an inner periphery of the cylinder 111 in a state that the key K is not inserted therein, thereby the rotor 112 is restrained from being rotated. On the other hand, when a proper key K is inserted into the rotor 112 , each tumbler 113 , 113 , . . . corresponding to an end surface of a mountain-groove shape of the key K engages with the end surface of the key K so that all of the tumblers 113 , 113 , . . . evacuate from the outer periphery of the rotor 112 . Thereby, it becomes possible to carry out rotation operation of the rotor 112 .
A slide piece 114 is mounted in the front lower side of the rotor 112 in the diameter direction in a movable state. The outer surface of the slide piece 114 is curved at the same curvature as that of the outer surface of the rotor 112 , so that the rotor 112 and the slide piece 114 are configured to be integrally rotated in the key cylinder 110 . In addition, in a state that the key K is inserted into the rotor 112 , the slide piece 114 is restrained from moving in the center direction of the rotor 112 by that the end portion thereof is brought into contact with a part of the key K.
An antilock lever 115 that is an elongated movable member is mounted in the lower part of the key cylinder 110 , parallel to the center axis of the key cylinder 110 and rotatably around a shaft of the central part thereof. A front end part 115 a is formed in the front end of the antilock lever 115 so as to be bent toward the slide piece 114 located at the upper position, and a back end part 115 b that is capable of engaging with an engaging projection 203 b of a slider 203 described below is formed in the back end thereof. Further, elastic force acts on the antilock lever 115 in a direction (elevating direction) from the front end part 115 a to the slide piece 114 by a spring or the like (not shown). In a state that the rotor 112 is located at the “LOCK” position or the key K is removed from the key cylinder 110 , the elastic force acts on the antilock lever 115 , thereby the front end part 115 a elevates and simultaneously the back end part 115 b descends so that the antilock state is released (steering lock allowing state).
A cam shaft 116 is formed so as to be combined with a rear shaft of the rotor 112 . The cam shaft 116 includes an outer tubular part 116 a having an approximately cylindrical shape and an inner tubular part 116 b having an approximately cylindrical shape similarly so that both are integrally formed at the front part in combination with each other. The rear shaft 112 b of the rotor 112 is fitted to an inner periphery of the inner tubular part 116 b of the cam shaft 116 , and simultaneously a rear end part of the inner tubular part 116 b projects from the case 101 so as to be combined with the ignition switch unit 40 . Thereby, the rotor 112 of the key cylinder 110 is operated to be rotated by the proper key K, so that the ignition switch unit 40 is operated via the cam shaft 116 .
A torsion spring 117 is housed in a space between the outer tubular part 116 a and the inner tubular part 116 b of the cam shaft 116 . One end of the torsion spring 117 engages with the outer tubular part 116 a of the cam shaft 116 , thus when the rotor 112 of the key cylinder 110 reaches an “ON” position by rotation operation of the key K, another end of the torsion spring 117 engages with the case 101 , thereby a spring force acts on the cam shaft 116 in the direction in which operation of the key K is returned from a “START” position to the “ON” position.
A cam surface 116 c is formed in a lower part of the outer tubular part 116 a of the cam shaft 116 , that slides in contact with a follower part 203 a of a slider 203 described below.
The steering lock part 20 includes a lock bar 201 , a compression spring 202 and the slider 203 . The lock bar 201 is formed of high stiffness metal so as to have a rod-like shape, and the distal end part thereof is mounted in a lower part of the steering lock device 1 so as to be movable back and forth from the case 101 to a side of the steering column 80 . In addition, a spring force always acts on the lock bar 201 in the direction in which it exits from the case 101 by the compression spring 202 housed in the case 101 .
In the case 101 , a groove part 201 b is formed in an upper part of the lock bar 201 , a lower part of the slider 203 is fitted to the groove part 201 b . Together with this, a rear surface of upper part of the slider 203 is brought into contact with an inner wall 101 c of rear part of the case 101 , thereby the lock bar 201 is prevented from falling out of the case 101 .
The follower part 203 a is integrally formed in an upper part of the slider 203 so as to follow in contact with the cam surface 116 c of the above-mentioned cam shaft 116 . In addition, an engaging projection 203 b capable of engaging with the rear end part 115 b of the above-mentioned antilock lever 115 is formed in an upper part of the front portion of the slider 203 .
Here, FIG. 3 is a cross-sectional view schematically showing parts of the lock bar 201 and the steering column 80 in the steering lock device 1 shown in FIG. 1 . A bracket 102 is formed so as to have a semicircular arc shape and one end is openable supported via a hinge shaft 102 a in a hinge block part 101 b of the case 101 . The bracket 102 is opened, the steering column 80 is fixed to the case 101 and another end is fixed to a boss block part 101 a via a bolt 103 in a state that the bracket 102 is closed, thereby the steering column 80 is mounted in the steering lock device 1 .
As shown in FIG. 3 , in a lock position in which the lock bar 201 advances toward a side of the steering column 80 , the distal end part 201 a of the lock bar 201 enters into a concave portion 82 a of a spline boss 82 fitted to the steering shaft 81 so as to engage therewith, thereby, the steering shaft 81 is restrained from being rotated. In addition, in an unlock position in which the lock bar 201 evacuates, the distal end part 201 a of the lock bar 201 and spline boss 82 does not engage with each other, the rotation restraint of the steering shaft 81 is released.
According to the above-mentioned configuration of the steering lock part 20 , in a state that the key K is removed from the key hole 112 a , the slide piece 114 is not restrained from moving, thereby slide piece 114 is elevated by the front end part 115 a of the antilock lever 115 , and simultaneously the back end part 115 b of the antilock lever 115 descends. Consequently, the engaging projection 203 b of the slider 203 and the back end part 115 b of the antilock lever 115 can not engage with each other, thus the lock bar 201 advances toward the lock position by the elastic expansion force of the compression spring 202 and simultaneously the rear surface of upper part of the slider 203 fitting to the groove part 201 b of the lock bar 201 is brought into contact with the inner wall of rear part of the case 101 , thereby the lock bar 201 is maintained in the lock position.
In the course that the proper key K is inserted into the key hole 112 a , and the rotor 112 is rotated from the “LOCK” position to the “ACC” position, the outer surface of the slide piece 114 moves to the position corresponding to the outer periphery of the rotor 112 , thereby the front end part 115 a of the antilock lever 115 is pushed downward, and simultaneously the rear end part 115 b of the antilock lever 115 is elevated. At this time, the cam shaft 116 is rotated in conjunction with rotation of the rotor 112 , thereby the slider 203 and the engaging projection 203 b in the front part of the slider 203 move forward together with the follower part 203 a that follows in contact with the cam surface 116 c of the cam shaft 116 , and further the lock bar 201 that fits to the slider 203 in the groove part 201 b evacuates to the unlock position. In addition, when the rotor 112 operated to be rotated reaches the “ACC” position, the engaging projection 203 b engages with the rear end part 115 b of the antilock lever 115 , thereby the slider 203 is held at the position, and simultaneously the lock bar 201 fitting to the slider 203 is held at the unlock position. Thereby, after the key K is operated to be rotated to the “ACC” position, the steering lock is made antilock so as to prevent the steering lock from malfunctioning.
Next, the interlock unit 30 as a key interlock device according to an embodiment of the present invention will be explained.
FIG. 4 is an exploded perspective view schematically showing an internal constitution of the interlock unit 30 as the key interlock device according to an embodiment of the present invention. As shown FIG. 4 , the interlock unit 30 includes a case member 31 and a cover member 32 , and a holding solenoid 33 , a link 34 , a release link 35 and a torsion spring 37 that are housed in the case member 31 and the cover member 32 .
The case member 31 is integrally formed of a resin material having good heat conductivity such as PBT containing glass fibers by an injection molding. The case member 31 has an outer shape of an approximate rectangle, and is formed so as to have a frame-like shape of which front and rear parts are mostly opened. When viewed in the insertion direction of the key K, at a bottom right part of the case member 31 , a screw bracket part 31 a having a hole 311 is formed to project, and at a bottom left part opposite to the screw bracket part 31 a , an engaging projection part 31 b is formed.
In addition, the inner part of the case member 31 in which the engaging projection part 31 b is formed is partially opened downward, and simultaneously a bearing part 31 c having a cylindrical shape is formed in the side wall part of the case member 31 . In addition, in two sites of rear end part of the case member 31 , fitting projection parts 31 e , 31 d having a pin-like shape are formed so as to project, and in a predetermined site of the outer wall part of the case member 31 , a plurality of engaging claws 31 f are formed.
The cover member 32 is formed of the same resin material as the case member 31 by an injection molding so as to have an approximately plate-like shape. The cover member 32 is a member mounted for blocking the open part in the rear side of the case member 31 , in which fitting hole parts 32 d , 32 e that fit to the fitting projection parts 31 e , 31 d of the case member 31 are formed, and a plurality of engaging frame parts 32 f that engage with the engaging claws 31 f of the case member 31 are formed so as to project. In addition, in the lower part of the cover member 32 corresponding to the bearing part 31 c of the case member 31 , a pin pole 32 c is formed so as to be opened. In addition, above the pin pole 32 c of the cover member 32 , an open part 32 g is formed by that a step part is opened, and simultaneously in the opening end of the open part 32 g , a spring engaging part 32 h is formed so as to project.
The holding solenoid 33 includes a plunger 331 and an engaging shaft 332 perpendicular to the plunger 331 . In addition, a harness connector 333 is mounted in the front part of the holding solenoid 33 . The holding solenoid 33 becomes in an excited state by that the driving current is supplied, so that the holding solenoid 33 generates holding force (attraction force) restraining the plunger 331 from projecting.
The holding solenoid 33 is housed in the case member 31 so as to expose the harness connector 333 from the open part of front side of the case member 31 to the outside.
The link 34 is a reinforcement member integrally formed of a synthetic resin material such as PBT containing glass fibers similarly to the case member 31 . The link 34 includes an arm part 34 c of a linear shape having a pressure receiving surface 34 a being flat-shaped in the right side when viewed from the insertion direction of the key K, a rotation shaft part 34 b formed in the left basic end side of the arm part 34 c , engaging groove parts 34 d , 34 d having a two-pronged portion bent at an approximately right angle at the position of the rotation shaft part 34 b , and a spring engaging part 34 e formed in the left front part of one of the engaging groove parts 34 d so as to project.
The release link 35 is a member formed of a resin material having good sliding characteristics such as POM, and has a taper surface 35 a having a downward-facing slope formed in the right side when viewed from the insertion direction of the key K. In addition, a bearing hole 35 b into which the rotation shaft part 34 b of the link 34 is inserted is formed in the end part opposite to the taper surface 35 a so as to be opened. The release link 35 is supported by the rotation shaft part 34 b of the link 34 at the bearing hole 35 b , thereby it is rotatably mounted relatively to the link 34 .
As shown in FIG. 4 , the torsion spring 37 is formed so as to have such a configuration that two spiral parts having the same diameter and axis are combined with each other at a combining part 37 c . The torsion spring 37 comes into contact with the release link 35 at the combining part 37 c , and the two spiral parts are respectively fitted to both end parts of the rotation shaft part 34 b of the link 34 so as to stride the link 34 and the release link 35 . In addition, simultaneously one end 37 a of the torsion spring 37 engages with the spring engaging part 34 e of the link 34 . Thereby, the link 34 and the release link 35 are prevented from being removed in the axis direction by being sandwiched between the two spiral parts of the torsion spring 37 and simultaneously elastic force acts in a direction of closing each other.
The link 34 and the release link 35 are rotatably mounted in the case member 31 by that one end part of the rotation shaft part 34 b of the link 34 is fitted to the bearing part 31 c of the case member 31 , and groove parts of the two-pronged portion of the engaging groove parts 34 d , 34 d are engaged with the engaging shaft 332 of the holding solenoid 33 . At this time, the arm part 34 c of the link 34 and the taper surface 35 a of the release link 35 are mounted so as to expose downward from the open part in the lower side of the case member 31 .
Then, another end part of the rotation shaft part 34 b of the link 34 is inserted into an bearing part (not shown) formed in the inner wall part of the pin hole 32 c of the cover member 32 , and a pin 36 formed of a metal is inserted into the pin hole 32 c so as to pass through the rotation shaft part 34 b of the link 34 . At the same time, the fitting projection parts 31 e , 31 d of the case member 31 were fitted to the fitting hole parts 32 d , 32 e of the cover member 32 , and the engaging frame parts 32 f of the cover member 32 is engaged with the engaging claws 31 f of the case member 31 , thereby the cover member 32 is mounted in the case member 31 .
In this state, another end 37 b of the torsion spring 37 remains projecting from the open part 32 g of the cover member 32 to the outside. The another end 37 b of the torsion spring 37 projecting to the outside is engaged with the spring engaging part 32 h while twisted in the direction in which the spiral parts are closed, thereby elastic force of the torsion spring 37 acts on the link 34 and the release link 35 in the direction in which the spiral parts are opened via the combining part 37 c . As a result, while the link 34 and the release link 35 are restrained by the holding solenoid 33 via the engaging groove parts 34 d , 34 d , parts of the arm part 34 c exposed from the case member 31 and the taper surface 35 a of the release link 35 provide elastic force downward.
FIG. 5 is a perspective view schematically showing an installation method of the interlock unit 30 as the key interlock device according to one embodiment of the present invention in the steering lock device 1 . As shown in FIG. 5 , in the steering lock device 1 , a housing frame part 101 d that houses the interlock unit 30 therein and a screw boss part 101 f are integrally formed with the case 101 at the installing position of the interlock unit 30 in the backward upper part of the key part 10 . In addition, an engaging hole 101 e is formed in the left side wall of the housing frame part 101 d so as to be opened.
The interlock unit 30 is mounted in the housing frame part 101 d of the steering lock device 1 by that the engaging projection part 31 b in the left side is inserted into the engaging hole 101 e of the housing frame part 101 d from the inside so as to be engaged with each other, and then a mounting screw 38 is inserted into the hole 311 of the screw bracket part 31 a so as to be fastened to a screw hole of the screw boss part 101 f.
FIG. 6A is a front view schematically showing an inner structure of the interlock unit 30 as the key interlock device according to one embodiment of the present invention when viewed from the insertion direction of the key K, in which the interlock unit 30 is in an interlock state. Similarly, FIG. 6B is a front view schematically showing an inner structure of the interlock unit 30 as the key interlock device according to one embodiment of the present invention, in which the interlock unit 30 is in a state that the interlock state is released.
In case that a shift lever of a vehicle is operated to a shift position other than “P (parking)”, driving current is supplied to the holding solenoid 33 from a control device (not shown). At this time, the holding solenoid 33 becomes in an excited state, thereby the position of the plunger 331 is held, and simultaneously the link 34 is restrained from being rotated via the engaging groove parts 34 d engaging with the engaging shaft 332 (the interlock state).
As shown in FIG. 6A , the link 34 transmits a rotation restraining force generated by the holding solenoid 33 in an excited state to the cam shaft 116 . In order to oppose against the rotation restraining force, the rotation shaft part 34 b and the pin 36 of the link 34 are arranged on an extension of a line of force of the rotation operation force of the key K generated in the tangential direction of the cam shaft 116 .
Namely, in case that the key K is operated so as to be returned from the “ACC” position to the “LOCK” position in the interlock state, the link 34 is restrained from being rotated by the holding solenoid 33 , so that a state that an action surface 116 d of the cam shaft 116 and the pressure receiving surface 34 a of the arm part 34 c of the link 34 are brought into contact with each other is maintained. Thereby, the rotation operation force by the key K is received at the rotation shaft part 34 b and the pin 36 passing through the rotation shaft part 34 b located on an extension of a line of force thereof, and simultaneously a rotation restraining force as the counteraction is transmitted to the cam shaft 116 via the link 34 , so that the rotation operation of the key K in the direction returning to the “LOCK” position is locked.
As shown in FIG. 6B , in case that a shift lever of a vehicle is operated to a shift position of “P (parking)”, the supply of driving current to the holding solenoid 33 is blocked, thereby the rotation restraint of the link 34 is released. Accordingly, when the key K is operated from the “ACC” position to the “LOCK” position in this state, the taper surface 35 a of the release link 35 runs upon an edge of the action surface 116 d of the cam shaft 116 , thereby the arm part 34 c of the link 34 on which elastic force acts toward the release link 35 by the torsion spring 37 is also rotated in conjunction therewith, thus the interlock state is released so that the rotation operation of the key K to the “LOCK” position is allowed.
As explained above, in accordance with the interlock unit 30 of the embodiment, the rotation shaft part 34 b for rotatably supporting the link 34 and the pin 36 penetrating through the rotation shaft part 34 b are disposed on a line of force of the rotation operation force generated in the tangential direction of the cam shaft 116 operated by the key K. The rotation operation force from the cam shaft 116 is received at the rotation shaft part 34 b and the pin 36 , thereby the burden of a load to the link 34 can be reduced. In addition, the arm part 34 c of the link 34 is formed so as to have a shape extending linearly from the rotation shaft part 34 b as a center, so that only compression load component acts on the arm part 34 c without bending stress component. The link mechanism of the above-mentioned configuration is adopted as a reinforcement part of the holding solenoid 33 , so that as a material of the link 34 and the like, a resin having high resistance to a compression load such as PBT can be used instead of metal, so that high production costs can be reduced.
In addition, according to the embodiment, such a structure is adopted, that the engaging projection part 31 b is formed in one end part of the interlock unit 30 , and the engaging projection part 31 b is engaged with the housing frame part 101 d of the steering lock device 1 so that the interlock unit 30 is mounted. Thereby, in comparison with a conventional case that two mounting bolts are fastened, the mounting process of the interlock unit 30 can be simplified so as to reduce the production costs.
In addition, according to the embodiment, such a structure is adopted, that the engaging projection part 31 b that allows the interlock unit 30 to engage with the steering lock device 1 is formed in a side (the left side when viewed from the insertion direction of the key K) on which the rotation operation force acts, the rotation operation force being directed toward the direction in which the key K is returned to the “LOCK” position at the interlock state. By the above-mentioned structure for installing in the steering lock device 1 , the rotation operation force from the cam shaft 116 can be received on the surface of the housing frame part 101 d of the steering lock device 1 instead of a conventional shear direction to the mounting bolts, thereby backlash, loose and the like that occur in the mounting part of the interlock unit 30 can be prevented, so that sufficient performance quality can be maintained.
Although the invention has been described with respect to the specific embodiments for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth.
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A key interlock device includes a solenoid that holds a plunger when the solenoid is excited, and a link member that includes a shaft around which the link member is rotatable, and engages with the plunger so as to transmit a restraining force opposing an operation force of a key when the solenoid is excited. The shaft of the link member is disposed on a virtual line extending from a line of force of the operation force of the key. The key interlock device may include an engaging part through which the key interlock device is attached to a body of a steering lock device and which is disposed behind the shaft to which the operation force of the key applies.
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FIELD OF THE INVENTION
This invention relates to an aqueous electroplating solution for high speed electroplating bright tin and tin-lead alloy solder coatings, and in particular, to an electroplating solution using volatile aldehyde brighteners and added diols to keep the aldehyde in solution.
BACKGROUND OF THE INVENTION
Electroplated tin and tin/lead alloy solder coatings are used extensively in the electronics industry in the manufacture of printed wiring boards (PWB), electrical contacts and connectors, semiconductor packaging, electrical conduits, and other related parts. These plated solder coatings must be pore free or corrosion resistant, display long term solderability and be free from solderability failures such as non-wetting and dewetting.
Bright plated solder coatings have distinct advantages over plated solder coatings with matte and satin bright finishes. Bright plated coatings, for example, are more readily subject to on-line automatic inspection. They are less likely to have plating stains and are cosmetically superior. Until recently, however, bright plated coatings with satisfactory solderability could be achieved only at low current densities, reducing the plating speed and profitability of bright plated parts.
U.S. Pat. No. 6,267,863 which issued to J. A. Abys et al. on Jul. 31, 2001 discloses a new electroplating solution for plating bright tin, lead or tin-lead alloy solder coatings at high speed. This application is incorporated herein by reference. The new solution comprises a sulfonic acid electrolyte, a non-ionic surfactant, a grain refiner and brightening agents comprising an aromatic aldehyde and a carboxylic acid. The new solution permits production of bright tin or tin-lead alloy solder coatings having very low organic (carbon) content at current densities as high as 1300 ASF. The result is high speed production of bright plated solder coatings with excellent reflowability and solderability.
One drawback of this process is that aldehyde brighteners are volatile. To prevent evaporative loss of the brighteners, the plating must be carried out at a reduced temperature, typically about 58° F. This necessitates the use of chillers, which are expensive and inconvenient. Accordingly it would be desirable to provide a less volatile bright solder plating bath so that plating can be carried out at room temperature and above.
SUMMARY OF THE INVENTION
In accordance with the invention, the volatility of a solder plating bath with volatile brighteners such as aldehydes has its volatility reduced by the addition of diols to the bath. The diols to the bath. The diols are advantageously 1, 3 propanediol or 1, 2 propanediol and are accompanied by lower molecular weight alcohols. In a preferred embodiment, a diol along with low alcohol is added to a bath comprising sulfonic acid, surfactant, grain refiner and brightening agents comprising an aromatic aldehyde and a carboxylic acid.
DETAILED DESCRIPTION
Bright plated solder coatings are achieved in the present invention using a tin or tin/lead electroplating solution based upon an alkane or alklanol sulfonic acid electrolyte which includes certain brightening additives that interact synergistically during electroplating to produce bright tin or tin-lead alloy solder coatings having very low organic (carbon) content at current densities as high as 1300 ASF. As should be apparent, the low organic content in the bright plated solder coatings is advantageous in providing the coatings with excellent reflowability and solderability.
The very low organic content in bright solder coating plated using the electroplating solution of the present invention makes them very useful in high speed continuous electroplating applications such as connectors, IC lead frames and other electronic components. The ability to achieve such low organic content at high current densities advantageously permits use of the electroplating solution in these high speed electroplating applications where high throughput and high productivity are possible.
The brightening additives used in the inventive electroplating solution consist of an aromatic aldehyde and a carboxylic acid. The aromatic aldehyde also functions as a leveling agent to improve the smoothness of the plated surface. The synergistic interaction of these two additives produces bright tin or tin-lead alloy solder coatings with very low organic content at relatively high current densities as shown in the above Table.
Some of the aromatic aldehydes which are useable in the electroplating solution include chlorobenzaldehyde, methoxybenzaldehyde, the allyl ether of 2-hydroxybenzaldehyde, and the derivatives of benzaldehyde which contain an electron donating group on the benzene ring. Some of the carboxylic acids which are useable in the electroplating solution of the invention include methacrylic acid, acrylic acid and their derivatives. In one embodiment, the aromatic aldehyde comprises chlorobenzaldehyde and the carboxylic acid comprises methacrylic acid.
To improve the dispersibility of the solution and suppress the growth of dendrites, a non-ionic surfactant and a grain refiner are added to the solution. The non-ionic surfactant improves the dispersibility of the solution and also ensures that the plated solder coatings adhere well to the underlying substrate. The grain refiner suppresses the growth of dendrites. Examples of suitable non-ionic surfactants include aromatic compounds such as substituted and unsubstituted phenyl and phenol compounds. Examples of suitable grain refiners include heterocyclic compounds such as substituted and unsubstituted lactones, cyclic imides, and oxazolines. In one embodiment, the non-ionic surfactant comprises a polyalkoxylated alkyl phenol, such as octylphenoxy (10) polyethoxy ethanol and the grain refiner comprises phenolphthalein.
To prevent evaporative loss of the brighteners, diols are added to the bath. The diols remain in the solution and they also keep the volatile brighteners in the solution. The aldehyde phase does not separate and does not evaporate as readily as in prior practice. In one embodiment the diol is 1, 3 propanediol or 1, 2 propanediol and it is advantageously accompanied by lower molecular weight alcohols.
The alkane or alkanol sulfonic acid electrolyte used in the solution should be water soluble or soluble in the solution. Suitable sulfonic acids include the lower alkane or alkanol sulfonic acids containing 1-5 carbon atoms. In one embodiment, the sulfonic acid electrolyte comprises methanesulfonic acid.
The tin and/or lead compounds typically used in the solution are those which are soluble in alkane or alkanol sulfonic acids and form an alkane or alkanol sulfonic acid salt. However, the tin and/or lead metals can be added to the baths in various forms and do not have to be added as a soluble alkane or alkanol sulfonate salt. Lead, for example, can be added as lead acetate. Thus, the solution can contain ions other than sulfonate ions as long as sufficient sulfonate ions are present to produce the advantages results of the invention. The metals should predominate as sulfonates in the baths.
A solution for electroplating a tin-lead alloy is typically prepared by adding about 70-90 g/l of the stannous sulfonate and about 8-12 g/l of the lead sulfonate to about 175-225 ml of the methanesulfonic acid. (A solution for electroplating either tin or lead can be prepared in the same manner by respectively omitting the lead or stannous sulfonate). To this solution are added about 2-2.25 g/l of octylphenoxy (10) polyethoxy ethanol, about 0.08-0.12 g/l of phenolphtalein, about 0.1-0.25 g/l of chlorobenzaldehyde, about 0.8-1.2 g/l of methacrylic acid, and about 1-2 g/l of propanediol (1,3 or 1,2).
After the solution is prepared, it can then be used in a high speed electroplating process for electroplating tin-lead alloy onto a metal substrate by placing the metal substrate in a electroplating solution equipped with a soluble tin anode. The electroplating solution is maintained at a temperature in the range of about room temperature to about 35 degrees C. The current densities used for electroplating are typically about 1300 ASF or less.
The substrate is maintained in the solution under the above conditions for a period of time that is sufficient to plate the substrate with a tin coating of a desired thickness. Typically, it is advantageous if the tin coating has a thickness of about 3 mu.m to about 6 mu.m.
EXAMPLE
A solution was prepared by adding 80 grams of stannous methane sulfonate and 10 grams of lead methyl sulfonate to one liter of an aqueous solution containing 200 ml of a 70 percent methane sulfonic acid. To this solution was added about 2 g/l of octylphenoxy (10) polyethoxy ethanol (commercially available under the tradename Triton X-100.RTM. from Union Carbide), about 0.08 g/l of phenolphthalein (commercially available from Fischer Scientific Co.) about 0.25 g/l of chlorobenzaldehyde (available from Aldrich), and about 1 g/l of methacrylic acid (available from Aldrich), and about 1.5 g/l of propanediol. The resulting solution was then used to plate a layer of tin-lead alloy on a substrate of copper, copper alloy or steel. The chlorobenzaldehyde did not separate and plating was carried out at room temperature and above.
While the foregoing invention has been described with reference to the above embodiments, various modifications and changes may be made without departing from the spirit of the present invention. Accordingly, modifications and changes such as those suggested above but not limited thereto are considered to be within the scope of the claims.
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In accordance with the invention, the volatility of a solder plating bath with volatile brighteners such as aldehydes has its volatility reduced by the addition of diols to the bath. The diols are advantageously 1,3 propanediol or 1,2 propanediol and are accompanied by lower molecular weight alcohols. In a preferred embodiment, a diol along with low alcohol is added to a bath comprising sulfonic acid, surfactant, grain refiner and brightening agents comprising an aromatic aldehyde and a carboxylic acid.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a composite plate material of a thermoplastic resin and reinforcing fibers (hereinafter referred to as FRTP plate) suitable in use for molding various products constructed from a composite material of the thermoplastic resin and reinforcing fibers (fiber reinforced thermoplastics, hereinafter referred to as FRTP) by stamping or press flow molding method etc., and relates to products molded out of the composite plate material or materials (hereinafter referred to as FRTP products).
2. Description of the Prior Art
Various FRTP plates are known. There are two types of FRTP plates, using excessively long reinforcing fibers and using excessively short reinforcing fibers. Typical FRTP plate of the former type comprises unidirectionally oriented reinforcing fibers, or reinforcing fibers formed as a fabric or a swirl mat. Typical FRTP plate of the latter type comprises reinforcing fibers formed as a chopped strand mat formation. Although both types of FRTP plates have respective characteristics, recently the former having higher mechanical properties has been more noted than the latter from the viewpoint of use of FRTP material for various mechanical parts which has been broadly developed.
The former type of FRTP plates, which use excessively long reinforcing fibers, are disclosed in, for example, JP-B-63-37694 and JP-A-60-36136. The FRTP plates disclosed in these publications are composites of thermoplastic resins and reinforcing fibers orientated in one direction parallel to one another in the form of a sheet. Since the reinforcing fibers are unidirectionally orientated in these FRTP plates, they are very suitable in the case where a product to be molded requires a directivity in its mechanical properties. However, in the case where a quasi isotropy is required for the mechanical properties of a product to be molded, it is required that a plurality of the FRTP plates must be laminated and arranged so as to gradually shift the directions of the reinforcing fibers of the laminated plates when the product is molded. In this molding, if the lamination structure of the FRTP plates is not adequately determined, the anisotropic properties of the molded product increase.
The FRTP plates of reinforcing fibers formed as a fabric or a swirl mat are disclosed in, for example, the above-described JP-B-63-37694, JP-B-48-8468 and JP-B-48-9958. The FRTP plates having these formations in reinforcing fibers have anisotropies smaller than those of the FRTP plates using unidirectionally orientated reinforcing fibers. However, the FRTP plate of reinforcing fibers formed as a fabric is not suitable for molding an FRTP product having a complicated shape such as a shape having many curved surfaces and/or many corners even if an FRTP product having a simple shape such as a plane plate can be easily molded, because the structural stability of a fabric, wherein warp fibers and weft fibers cross crimp each other, is high, and therefore, the fittability of the FRTP plate in molding to a complicated shape is not good. Also in the FRTP plate of reinforcing fibers formed as a swirl mat, the fittability thereof is not good though the anisotropic properties thereof are smaller than those of the FRTP plate of a reinforcing fiber fabric. Therefore, it is difficult to uniformly distribute the reinforcing fibers in a molded FRTP product because the reinforcing fibers of the FRTP plate lack in fluidity during molding.
On the other hand, the FRTP plate of excessively short reinforcing fibers formed as a chopped strand mat has an excellent fittability higher than that of any above-described FRTP plate, and can be relatively easily served to mold an FRTP product having a complicated shape. However, since the reinforcing fibers are short and it is difficult to increase the volume content of the reinforcing fibers in the FRTP plate or the FRTP product, the reinforcement effect due to the reinforcing fibers cannot be greatly increased, and therefore, the mechanical properties of the molded FRTP product are not high.
To solve such a problem, JP-A-59-62112 proposes that, after a thermoplastic resin is impregnated into or applied on the bundle of reinforcing fibers, the bundle including the thermoplastic resin is cut to many bundle pieces each of which has an excessively long length comparing to its width, the bundle pieces are disposed in a required form and the disposed bundle pieces are heated and pressed. According to this process, the thermoplastic resin is impregnated into the reinforcing fibers more completely and the volume content of the reinforcing fibers can be increased to some extent. Therefore, the mechanical properties of the molded FRTP product using the bundle pieces also can be increased to some extent. However, the degree of the increase is not sufficient to satisfy the objects of the present invention at all.
Moreover, the common problem in FRTP materials or FRTP products comprising relatively short reinforcing fibers is that the impact resistance thereof is relatively low.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an FRTP plate having both the advantage of high mechanical properties caused by using fairly long reinforcing fibers and the advantage of good fittability caused by using fairly short reinforcing fibers, thereby easily molding an FRTP product having high mechanical properties.
Another object of the present invention is to provide an FRTP plate having an excellent quasi-isotropic property, thereby making a quasi-isotropic FRTP product easily.
A further object of the present invention is to provide various molded FRTP products which can have excellent mechanical properties by using the FRTP plates.
To accomplish the above objects, a composite plate material (FRTP plate) according to the present invention has a quasi isotropy in plane thereof and comprises a thermoplastic resin having a melt viscosity of 1,000-15,000 poise at the temperature which the composite plate material is formed and strip pieces each constructed of unidirectionally orientated reinforcing fibers. The strip pieces are randomly distributed in plane parallel to a surface of the FRTP plate. Each of the strip pieces has the dimensions of a) the thickness not greater than 0.2 mm, b) the width in the direction perpendicular to the reinforcing fiber orientated direction in the range of 2-25 mm, c) the length in the reinforcing fiber orientated direction in the range of 5-30 mm, and d) the ratio of the width and the length in the range of 0.15-1.5.
The FRTP plate according to the present invention comprises a thermoplastic resin and strip pieces of reinforcing fibers. The thermoplastic resin has a melt viscosity of 1,000-15,000 poise at the temperature which the FRTP plate is formed. Each of the strip pieces is constructed of unidirectionally orientated reinforcing fibers. Each of the strip pieces is formed as a small composite plate piece 1, constructed of unidirectionally orientated reinforcing fibers 2 and a thermoplastic resin 3 pre-impregnated into the reinforcing fibers as shown in FIG. 2, or formed as a strip piece constructed of only unidirectionally orientated reinforcing fibers, as described later. The strip pieces are randomly distributed in plane parallel to a surface of a composite plate (FRTP plate) 4, and the FRTP plate 4, as shown in FIG. 1, is composed of reinforcing fibers 2 and the thermoplastic resin 3 in the manners described later.
In the FRTP plate according to the present invention, a thermoplastic resin having a melt viscosity of 1,000-15,000 poise at the temperature which the FRTP plate is formed can be used. As such a thermoplastic, polyamide resin such as nylon 6, nylon 66, nylon 610 and nylon 612, or co-polyamide resin of these polyamide resins can be used. Also, polyester resin such as polyethylene terephthalate and polybutylene terephthalate, or co-polyester resin of these polyester resins can be used. Further, a thermoplastic resin such as polycarbonate, polyamide-imide, polyphenylene sulfide, polyphenylene oxide, polysulfone, polyether sulfone, polyether-ether-ketone, polyolefin and polyether-imide can be used. Furthermore, the thermoplstic resin can be selected from thermoplastic elastomers such as polyurethane elastomer, polyester elastomer and polyamide elastomer.
The melt viscosity of the thermoplastic resin at a temperature which the FRTP plate is formed is measured by a capilary type viscometer. The actual measurement is carried out at just or near the temperature which the FRTP plate is formed and in the area of low shear rate, S in FIG. 3 which shows the typical relationship between shear rate and melt viscosity. As shown in FIG. 3, there are almost no effects of the shear rate on the melt viscosity in the area S. The measurement temperature is selected from the range higher than the melting point and lower than the decomposition point in a crystalline resin and from the range higher than the softening point and lower than the decomposition point in a non-crystalline resin.
The reinforcing fibers are selected as at least one kind of fibers from high strength and high elastic modulus fibers such as carbon fibers, glass fibers, polyaramid fibers, alumina fibers, alumina-silica fibers and silicon carbide fibers. The content of the reinforcing fibers is in the range of 20-60 vol.%, preferably 30-50 vol.%.
In the present invention, the FRTP plate or the FRTP product can have a hybrid structure by using two or more kinds of thermoplastic resins and/or two or more kinds of reinforcing fibers.
In the FRTP plate according to the present invention, the melt viscosity of the thermoplastic resin and the length and width of the strip piece are very important to achieve the aforementioned objects.
Since the strip pieces are randomly distributed in plane parallel to a surface of the FRTP plate, the strip pieces are laminated at least partially to one another. Thus, there exist fine clearances in the laminated portions, or portions where the thermoplastic resin is rich if the thermoplastic resin is not uniformly impregnated into the reinforcing fibers. A stress concentration occurs predominantly at these portions, when an external force is applied and the fracture of the FRTP plate starts at the portions and propagates. The melt viscosity of the thermoplastic resin is very important to prevent this stress concentration. Namely, if the melt viscosity of the thermoplastic resin is lower than 1,000 poise, the thermoplastic resin is liable to stick out from the strip piece of the reinforcing fibers and/or the alignment of the reinforcing fibers is liable to be disturbed by the excessive flow of the resin, when the resin is impregnated into the reinforcing fibers. The sticking out of the thermoplastic resin causes the non-uniform distribution of the reinforcing fibers in the resin of the FRTP plate, thereby causing stress concentration at the non-uniform portions and deterioration of the mechanical properties of the FRTP plate and the FRTP product. The disturbance of the reinforcing fibers also causes the deterioration of the mechanical properties. If the melt viscosity of the thermoplastic resin is higher than 15,000 poise, the impregnation of the resin into the reinforcing fibers deteriorates. Further, even if the impregnation of the thermoplastic resin is not so bad, the clearances at the laminated portions of the strip pieces in the FRTP plate are liable to remain because the configuration holding ability of each strip piece including the thermoplastic resin increases.
Thus, the melt viscosity of the thermoplastic resin is important to form an FRTP plate which has no clearances at the positions where the strip pieces laminate to one another and which has no resin-rich portion. Moreover, if the melt viscosity of the thermoplastic resin in the FRTP plate is in the above-described range (i.e. 1,000-15,000 poise), the reinforcing fibers impregnated with the resin appropriately move, the fittability of the FRTP plate improves and the distribution of the reinforcing fibers in an FRTP product becomes more uniform when the FRTP plate is heated and pressed to mold the FRTP product, because the temperature of the molding for the FRTP product is generally similar to the temperature at which the FRTP plate is formed.
The thickness of the strip pieces is not greater than 0.2 mm in the present invention. By observing carefully the failure process in the FRTP plate to which an external force is being applied, it is understood that the stress to be distributed uniformly along the reinforcing fibers concentrates at the positions where the strip pieces laminate to one another and the lamination positions are apt to become starting points for the breakage of the FRTP plate. This is caused by such a lamination state as shown in FIG. 4 wherein the strip piece 5 of the reinforcing fibers is bent in the thickness direction of the strip piece at the lamination position 6 and the position near the lamination position. The thickness of the strip pieces must be sufficiently small to suppress the stress concentration due to the bending of the strip pieces to a small extent. From this point of view, the thickness of the strip pieces in the present invention is determined to be not greater than 0.2 mm, preferably 0.1 mm. The thickness of the strip piece in the present invention means the thickness of the reinforcing fibers constituting the strip piece. In the case where the thermoplastic resin is pre-impregnated into the reinforcing fibers constituting the strip piece to form a small composite plate piece constructed of the thermoplastic resin and the reinforcing fibers, the thickness of the strip piece of the reinforcing fibers can be measured in the cross section of the small composite plate piece. However, the thickness of the strip pieces constructed of the reinforcing fibers can be determined to be almost the same as the thickness t (FIG. 2) of the small composite plate piece constructed of the reinforcing fibers and the thermoplastic resin in the present invention.
With respect to the relationship between the width W (FIG. 2) of the strip piece and the mechanical properties of the FRTP plate, the width of the strip piece greatly affects the impact resistance of the FRTP plate. Namely, the larger the width of the strip piece is, the higher the Charpy or Izod impact strength of the strip piece becomes. This is due to the fact that each strip piece impregnated with the thermoplastic resin is regarded as a small FRTP plate including unidirectionally orientated reinforcing fibers, such a small FRTP plate can have a high deformation resistance in accordance with bending, buckling or shear, and therefore, the small FRTP plate (the strip piece including the resin) having a larger width is more profitable for increase of its impact resistance.
On the other hand, when the failure mode of the FRTP plate to which an external force was applied is observed, it is revealed that the initial breakage occurs at the end positions of the strip pieces in the direction parallel to the reinforcing fibers because the stress due to the external force concentrates on the end portions of the reinforcing fibers. Therefore, if the width of the strip pieces is large too much in comparison with the length L (FIG. 2) of the strip pieces, the FRTP plate cannot have high mechanical properties because the area or the rate of the stress concentrated portions in the FRTP plate increases. Accordingly, an adequate range to be selected exists with respect to the relationship between the width and length of the strip piece. In the present invention, the width of the strip piece is set in the range of 2-25 mm, preferably 5-20 mm, and the ratio of the width and length of the strip piece is set in the range of 0.15-1.5, preferably 0.2-1.0. If the width of the strip pieces is smaller than 2 mm, it is difficult to present the above-described operation of the small composite plate piece constructed of the reinforcing fibers and the thermoplastic resin, and the impact resistance of the FRTP plate decreases. If the width of the strip pieces is larger than 25 mm, the impact resistance and other mechanical properties of the FRTP plate also decreases because the degree of the stress concentration at the end portions of the strip pieces increases. Since the affection at the end portions of the strip pieces to the stress concentration is also connected with the length of the strip pieces, however, if the ratio of the width and length of the strip pieces is smaller than 0.15, i.e. the strip pieces are longer and more slender pieces, the impact resistance of the FRTP plate decreases from the above-described reason even if the affection at the end portions of the strip pieces decreases. On the other hand, if the ratio is larger than 1.5, the affection at the end portions of the strip pieces increases, and therefore, an FRTP plate having high mechanical properties cannot be obtained.
The relationship between the rigidity of such an FRTP plate according to the present invention and the length of the reinforcing fibers used for the FRTP plate can be determined by modified Halpin-Tsai equation (J. C. Halpin, J. of Composite Materials, vol. 3, page 732, 1969). According to this equation, the longer the reinforcing fibers are, the higher the rigidity of the FRTP plate becomes, but if the length of the reinforcing fibers is larger than a certain value, the contribution due to the length of the reinforcing fibers to the increase of the rigidity decreases. On the other hand, in a press flow molding method, for example, the reinforcing fibers having a smaller length can move more easily, thereby obtaining an FRTP product having a complicated shape more easily. From these points of view, the length of the reinforcing fibers, i.e. the length of the strip pieces, must be selected from the range of 5-30 mm, more preferably 10-25 mm, to form an FRTP plate excellent in practical use and having high mechanical properties. If the length of the strip pieces is smaller than 5 mm, the rigidity of the FRTP plate and the FRTP product obtained decreases to a great extent. Moreover, the width of the strip pieces must be reduced corresponding to the small length of the strip pieces to ensure high flexural properties, but the FRTP plate or product using such strip pieces deteriorates in impact resistance. If the length of the strip pieces is larger than 30 mm, it is difficult to obtain a good quasi-isotropic property of the FRTP plate and uniformly distribute the reinforcing fibers in the FRTP plate and FRTP product because the fluidity of the reinforcing fibers decreases in forming process of the FRTP plate and molding process of the FRTP product, even if the rigidity of the FRTP plate or product increases.
The FRTP plate according to the present invention is formed as follows.
In a first method, the strip pieces are made as small composite plate pieces constructed of the reinforcing fibers and the thermoplastic resin pre-impregnated thereinto before the FRTP plate is formed. For example, the bundle of reinforcing fibers is continuously coated with the molten thermoplastic resin by extrusion, the coated bundle of reinforcing fibers is passed between a pair of rollers heated at a temperature higher than the melting point of the thermoplastic resin, the impregnation of the resin into the reinforcing fibers and the flattening of the bundle including the resin and the reinforcing fibers are carried out by pressing the bundle between the pair of rollers, and thereafter, the bundle flattened and impregnated with the resin is cut at a predetermined length to make strip pieces including the reinforcing fibers and the thermoplastic resin. Alternatively, the bundle of reinforcing fibers already impregnated with the thermoplastic resin is continuously touched onto a bar heated at a temperature higher than the melting point of the thermoplastic resin, the bundle is widened and flattened, and thereafter, the bundle is cut at a predetermined length to make strip pieces.
The strip pieces including the thermoplastic resin are randomly distributed in a cavity of a mold in order that they are randomly oriented in plane parallel to a surface of an FRTP plate to be formed. Then the mold is closed, and the distributed strip pieces are heated and pressed to form the FRTP plate by compression molding.
In a second method, the strip pieces are made as pieces constructed of only reinforcing fibers before the step of forming the FRTP plate. For example, the bundle of the reinforcing fibers impregnated with a sijing agent is widened to predetermined width and thickness, the widened bundle is cut at a predetermined length to make strip pieces of the reinforcing fibers, and the strip pieces with a required cut length are randomly distributed in plane parallel to a surface of an FRTP plate to be formed. The powder of thermoplastic resin are scattered on the distributed strip pieces or the distributed strip pieces are sandwiched by films of thermoplastic resin, and the strip pieces with the thermoplastic resin powder or the strip pieces sandwiched by the thermoplastic resin films are heated and pressed at a temperature higher than the melting point of the thermoplastic resin to form the FRTP plate required.
In the FRTP plate thus obtained, the strip pieces of the unidirectionally orientated reinforcing fibers are randomly distributed in plane parallel to a surface of the FRTP plate and the strip pieces are randomly laminated and connected to one another by the thermoplastic resin. This random lamination and distribution of the strip pieces results in the sufficient quasi-isotropic properties of the FRTP plate in plane thereof. In the present invention, that an FRTP plate is a quasi-isotropic means that the FRTP plate is in the status wherein the mechanical properties of the FRTP plate in any two directions perpendicular to each other and in the direction with an angle of 45 degrees to the above directions in the plane of the FRTP plate are in the range of±10% in the dispersion of the mechanical properties.
The FRTP plate according to the present invention has the thickness of, for example, 0.5-20 mm, more preferably 2-10 mm, and includes a relatively thin plate which is generally called a sheet.
The FRTP plate or plates obtained are served to mold various FRTP products as described later in examples.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate several embodiments of the invention and together with the description serve to explain the principles of the invention.
FIG. 1 is a perspective view of a composite plate according to an embodiment of the present invention.
FIG. 2 is a perspective view of a strip piece including a thermoplastic resin used for forming the composite plate shown in FIG. 1.
FIG. 3 is a graph showing a typical relationship between the melt viscosity and the shear rate of a thermoplastic resin and a measurement area for determining the melt viscosity of the thermoplastic resin according to the present invention.
FIG. 4 is a side view of two strip pieces including a thermoplastic resin, showing an example of the lamination state of the strip pieces according to the present invention.
FIGS. 5A and 5B are vertical sectional views of molds and composite plates used in a test for determining the fluidity of reinforcing fibers included in the composite plates.
FIGS. 6A and 6B are vertical sectional views of molds and composite plates showing the molding of an FRTP product according to an embodiment of the present invention, and FIG. 6C is a perspective view of the molded FRTP product.
FIGS. 7A and 7B are vertical sectional views of molds and composite plates showing the molding of another FRTP product according to another embodiment of the present invention, and FIG. 7C is a perspective view of the molded FRTP product.
FIGS. 8A and 8B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, FIG. 8C is a plan view of the molded FRTP product and FIG. 8D is an elevational view of the molded FRTP product.
FIGS. 9A and 9B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, FIG. 9C is a plan view of the molded FRTP product and FIG. 9D is an elevational view of the molded FRTP product.
FIGS. 10A and 10B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, FIG. 10C is a plan view of the molded FRTP product and FIG. 10D is a side view of the molded FRTP product.
FIGS. 11A and 11B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, and FIG. 11C is a perspective view of the molded FRTP product.
FIGS. 12A and 12B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, FIG. 12C is a plan view of the molded FRTP product and FIG. 12D is a side view of the molded FRTP product.
FIGS. 13A and 13B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, and FIG. 13C is a perspective view of the molded FRTP product.
FIGS. 14A and 14B are vertical sectional views of molds and composite plates showing the molding of a further FRTP product according to a further embodiment of the present invention, and FIG. 14C is a perspective view of the molded FRTP product.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some preferred embodiments of the present invention will be described hereunder with reference to the attached drawings.
EXAMPLE 1-3, COMPARATIVE EXAMPLES 1 and 2
In Example 1, the nylon 6 "AMILAN" CM1010 (the melt viscosity at 250° C.: 3,000 poise) produced by Toray Industries, Inc. is extruded at 260° C. around the glass multifilament "ER550" (the diameter of a single filament: 17 μm, the number of filaments: 1,000) produced by Nippon Electric Glass Co., Ltd., and a glass multifilament coated with nylon 6, having glass fiber content of 40 vol.%, is obtained. After the obtained glass multifilament with nylon 6 is preheated to a temperature of 260° C. by a far infrared radiation heater, the glass multifilament with nylon 6 is pressed by a pair of rollers heated at 260° C. to form a tape having the width of 6 mm and the thickness of 0.09 mm.
The tape obtained is cut to make strip pieces impregnated with nylon 6 and having the length of 6 mm. When the cross section of each strip piece obtained is observed, it is evident that the glass fibers are distributed up to both the surfaces of the strip piece, and therefore, the thickness of the glass fibers constituting the strip piece is substantially the same as that of the strip piece including the nylon 6. The strip pieces are distributed in a cavity of a mold, and compression molded at 260° C. to form an FRTP plate having the thickness of 3 mm. Thus the FRTP plate according to an embodiment of the present invention is obtained.
In Example 2, the length of strip pieces is set to 13 mm. Other conditions are the same as those in Example 1.
In Example 3, the length of strip pieces is set to 25 mm. Other conditions are the same as those in Example 1.
In Comparative Example 1, the length of strip pieces is set to 3 mm. Other conditions are the same as those in Example 1.
In Comparative Example 2, the length of strip pieces is set to 40 mm. Other conditions are the same as those in Example 1.
According to ASTM-D-790, the samples are made from the FRTP plates obtained in Examples 1 to 3 and Comparative Examples 1 and 2, and the flexural properties (flexural strength and flexural modulus) of the respective of samples are determined. As shown in Table 1, the flexural properties of the FRTP plate having the longer strip pieces i.e. longer glass fibers can increase in comparison with those of the FRTP plate having the shorter strip pieces.
TABLE 1______________________________________ Length of Flexural Flexural strip piece strength modulus (mm) (kgf/mm.sup.2) (kgf/mm.sup.2)______________________________________Com. Ex. 1 3 21 1130Ex. 1 6 27 1210Ex. 2 13 31 1250Ex. 3 25 41 1300Com. Ex. 2 40 43 1320______________________________________
Nest, the samples extending in the direction of angles of 0 degree, 45 degrees and 90 degrees on the respective FRTP plates obtained in Examples 1, 2 and 3 are taken out from the respective FRTP plates. The flexural properties of the respective samples of each FRTP plate are determined. As shown in Table 2, it is understood that all the FRTP plates obtained in Examples 1 to 3 are good quasi-isotropic in their plane directions.
TABLE 2______________________________________ Flexural strength Flexural modulus (kgf/mm.sup.2) (kgf/mm.sup.2)Angle 0° 45° 90° 0° 45° 90°______________________________________Ex. 1 27 28 27 1210 1230 1200Ex. 2 31 29 32 1250 1210 1290Ex. 3 41 38 40 1300 1350 1340______________________________________
Next, the respective FRTP plates obtained in Examples 1 to 3 and Comparative Examples 1 and 2 are heated at 280° C. by a far infrared radiation heater, and the same kind of the heated FRTP plates 11a and 11b are stacked by two in a cavity 12 of an lower mold 13 as shown in FIG. 5A. The cavity 12 has a cylindrical recessed portion 14 having the depth of 10 mm and the inner diameter of 10 mm on its central portion. An upper mold 15 is closed and pressed at a pressure of 100 kgf/cm 2 to mold an FRTP product 16 having the thickness of 4 mm in its plate portion and the projection 17 (height: 10 mm, diameter: 10 mm) in its central portion, as shown in FIG. 5B.
After molding respective FRTP products 16, projections 17 are cut away from the respective FRTP plates, nylon 6 is burnt off from the respective cut projections, and the volume contents of the glass fibers in the respective projections are determined by measuring the volumes of the remaining glass fibers in the respective burnt projections. As shown in Table 3, in the projection molded from the FRTP plates obtained in Comparative Example 2 wherein the length of the glass fibers is larger than the range according to the present invention, the volume content of the glass fibers is low because the glass fibers do not sufficiently flow into the projection portion.
TABLE 3______________________________________ Length of Volume content strip piece of glass fibers (mm) (vol. %)______________________________________Com. Ex. 1 3 40Ex. 1 6 40Ex. 2 13 40Ex. 3 25 37Com. Ex. 2 40 28______________________________________
EXAMPLES 4 AND 5, COMPARATIVE EXAMPLES 3 AND 4
In Example 4, a nylon 6 having the melt viscosity of 3,000 poise at 260° C. is extruded at 260° C. around the bundle of carbon fibers "TORAYCA" T300-6K (the diameter of a single fiber: 7 μm, the number of fibers: 6,000) produced by Toray Industries, Inc., and a bundle of carbon fibers coated with nylon 6, having carbon fiber content of 30 vol.%, is obtained. After the obtained carbon fiber bundle with nylon 6 is preheated to a temperature of 260° C. by a far infrared radiation heater, the bundle with nylon 6 is pressed by a pair of rollers heated at 260° C. to form a tape having the width of 6 mm and the thickness of 0.13 mm.
The tape obtained is cut to make strip pieces impregnated with nylon 6 and having the length of 13 mm. The strip pieces are distributed in a cavity of a mold, and compression molded at 260° C. to form an FRTP plate having the thickness of 3 mm.
In Example 5, a nylon 6 having the melt viscosity of 12,000 poise at 260° C. is used. Other conditions are the same as those in Example 4.
In Comparative Example 3, a nylon 6 having the melt viscosity of 500 poise is used. Other conditions are the same as those in Example 4. In this Comparative Example, there are many portions where the nylon 6 have sticked out from the strip pieces of carbon fibers, and the width of the strip pieces disperses relatively greatly.
In Comparative Example 4, a nylon 6 having the melt viscosity of 17,000 poise is used. Other conditions are the same as those in Example 4. In this Comparative example, the nylon 6 cannot uniformly impregnate into the bundle of carbon fibers, and the obtained strip pieces with the nylon 6 have voids.
According to ASTM-D-790, the samples are made from the FRTP plates obtained in Examples 4 and 5 and Comparative Examples 3 and 4, respectively, and the flexural strength of the respective samples are determined. As shown in Table 4, the flexural strength of the FRTP plate using nylon 6 having the melt viscosity of 500 poise lower than the range according to the present invention or the melt viscosity of 17,000 poise higher than the range, is lower than that of the FRTP plate using nylon 6 having a melt viscosity within the range.
TABLE 4______________________________________ Melt viscosity Flexural strength (poise) (kgf/mm.sup.2)______________________________________Com. Ex. 3 500 25Ex. 4 3,000 31Ex. 5 12,000 29Com. Ex. 4 17,000 17______________________________________
EXAMPLES 6-9, COMPARATIVE EXAMPLES 5 AND 6
In Example 6, the bundle of carbon fibers "TORAYCA" T300-12K (the diameter of a single fiber: 7 μm, the number of fibers: 12,000) is used, and a tape with nylon 6 having the thickness of 0.09 mm and the width of 24 mm is obtained in a manner similar to that in Example 1. Strip pieces having the length of 25 mm and the width of 6 mm are made from the tape, and an FRTP plate is made using the strip pieces in the same manner as that in Example 1.
In Example 7, strip pieces are cut at the length of 25 mm and the width of 12 mm. Other conditions are the same as those in Example 6.
In Example 8, strip pieces are cut at the length of 25 mm and the width of 24 mm. Other conditions are the same as those in Example 6.
In Example 9, strip pieces are cut at the length of 20 mm and the width of 24 mm. Other conditions are the same as those in Example 6.
In Comparative Example 5, strip pieces are cut at the length of 25 mm and the width of 2 mm. In Comparative Example 6, strip pieces are cut at the length of 13 mm and the width of 24 mm. Other conditions are the same as those in Example 6.
According to ASTM-D-256, the samples are made from the FRTP plates obtained in Examples 6 to 9 and Comparative Examples 5 and 6, and unnotched Izod impact tests are carried out with respect to the respective samples. As shown in Table 5, the impact resistance of the FRTP plate using the strip pieces having the ratio of the width and the length lower than the range according to the present invention or the ratio higher than the range, is lower than that of the FRTP plate using the strip pieces having a ratio within the range.
TABLE 5______________________________________Length of Width of Ratio of Izod impactstrip piece strip piece width/ value(mm) (mm) length (kgf.cm/cm.sup.2)______________________________________Com. Ex. 5 25 2 0.08 25Ex. 6 25 6 0.24 40Ex. 7 25 12 0.48 42Ex. 8 25 24 0.96 38Ex. 9 20 24 1.20 35Com. Ex. 6 13 24 2.08 28______________________________________
EXAMPLES 10 AND 11, COMPARATIVE EXAMPLE 7
In Example 10, the bundle of carbon fibers "TORAYCA" T300-12K (the diameter of a single fiber: 7 μm, the number of fibers: 12,000) is used, and the bundle coated with nylon 6 is obtained in a manner similar to that in Example 1. After the carbon fiber bundle with nylon 6 is preheated to a temperature of 260° C. by a far infrared radiation heater, the bundle is pressed between a pair of rollers which are heated to a temperature of 260° C., one of which has a groove extending in the circumferential direction of the roller and having the width of 12 mm and the other of which has a projection extending in the circumferential direction of the roller and having the width corresponding to the width of the groove, to make a tape having the width of 12 mm and the thickness of 0.08 mm. Strip pieces including nylon 6 and having the length of 25 mm are made by cutting the tape. The strip pieces obtained are distributed in a cavity of a mold, and the distributed strip pieces are compression molded at 260° C. to form an FRTP plate having the thickness of 3 mm.
In Example 11, two bundles coated with nylon 6, which are obtained in Example 10, are laminated to each other, and the laminated bundles are pressed by the pair of rollers used in Example 10 to make a tape having the width of 12 mm and the thickness of 0.16 mm. The tape obtained is cut to strip pieces having the length of 25 mm, and an FRTP plate having the thickness of 3 mm is formed using the strip pieces in the same manner as that in Example 10.
In Comparative Example 7, three bundles coated with nylon 6, which are obtained in Example 10, are laminated to each other, and the laminated bundles are pressed by the pair of rollers used in Example 10 to make a tape having the width of 12 mm and the thickness of 0.24 mm. The tape obtained is cut to strip pieces having the length of 25 mm, and an FRTP plate having the thickness of 3 mm is formed using the strip pieces in the same manner as that in Example 10.
The flexural properties of the FRTP plates obtained in the above Examples 10 and 11 and Comparative Example 7 are determined in the same manner as that in Example 1. As shown in Table 6, the flexural strength and flexural modulus of the FRTP plate using the strip pieces having the thickness larger than the range according to the present invention, are lower than those of the FRTP plates using the strip pieces having the thickness within the range.
TABLE 6______________________________________Length of Thickness of Flexural Flexuralstrip piece strip piece strength modulus(mm) (mm) (kgf/mm.sup.2) (kgf/mm.sup.2)______________________________________Ex. 10 25 0.08 50 2,500Ex. 11 25 0.16 48 2,430Com. Ex. 7 25 0.24 35 2,300______________________________________
EXAMPLE 12
The polybutylene terephthalate "PBT1100" (the melt viscosity at 250° C.: 4,000 poise) produced by Toray Industries, Inc. is extruded at 270° C. around the glass multifilament "RS57PR-452SS" (the diameter of a single filament: 13 μm, the number of filaments: 1,700) produced by Nittobo Glass Fiber Co., Ltd., and a glass multifilament coated with the polybutylene terephthalate, having glass fiber content of 40 vol.%, is obtained. After the glass multifilament obtained is preheated to a temperature of 270° C. by a far infrared radiation heater, the glass multifilament is pressed by a pair of rollers heated at 270° C. to form a tape having the width of 6 mm and the thickness of 0.09 mm.
The tape obtained is cut to make strip pieces impregnated with polybutylene terephthalate and having the length of 25 mm. The strip pieces are distributed in a cavity of a mold, and compression molded at 260° C. to form an FRTP plate having the thickness of 3 mm.
According to ASTM-D-790 and D-256, the samples are made from the FRTP plate, and the flexural strength, flexural modulus and Izod impact value of the FRTP plate are determined as shown in Table 7.
EXAMPLE 13
The polyether sulfone "VICTREX" 4100G (the melt viscosity at 350° C.: 10,000 poise) produced by Imperial Chemical Industries, PLC. is extruded at 375° C. around the bundle of carbon fibers "TORAYCA" T300-6K produced by Toray Industries, Inc. and a bundle of carbon fibers coated with the polyether sulfone, having carbon fiber content of 40 vol.%, is obtained. After the carbon fiber bundle obtained is preheated to a temperature of 380° C. by a far infrared radiation heater, the bundle is pressed by a pair of rollers heated at 350° C. to form a tape having the width of 6 mm and the thickness of 0.09 mm.
The tape obtained is cut to make strip pieces impregnated with polyether sulfone and having the length of 25 mm. The strip pieces are distributed in a cavity of mold, and compression molded at 375° C. to form an FRTP plate having the thickness of 3 mm.
The flexural strength, flexural modulus and Izod impact value of the FRTP plate are determined in the same manner as that in Example 12 and the resulted data are shown in Table 7.
EXAMPLE 14
The polyether imide "ULTEM" 1000 (melt viscosity at 370° C.: 10,000 poise) produced by General Electrics Co. Ltd. is extruded at 375° C. around the bundle of carbon fibers "TORAYCA" T300-6K and a carbon fiber bundle coated with the polyether imide, having carbon fiber content of 40 vol.%, is obtained. After the carbon fiber bundle obtained is preheated to a temperature of 380° C. by a far infrared radiation heater, the bundle is pressed by a pair of rollers heated at 360° C. to form a tape having the width of 6 mm and the thickness of 0.09 mm.
The tape obtained is cut to make strip pieces impregnated with polyether imide and having the length of 25 mm. The strip pieces are distributed in a cavity of a mold, and compression molded at 375° C. to form an FRTP plate having the thickness of 3 mm.
The flexural strength, flexural modulus and Izod impact value of the FRTP plate are determined in the same manner as that in Example 12 and the resulted data are shown in Table 7.
EXAMPLE 15
An FRTP plate is formed in the same manner as that in Example 2 other than using nylon 6 "AMILAN" CM1016-K (the melt viscosity at 250° C.: 3,000 poise) produced by Toray Industries, Inc.
According to ASTM-D-790 and D-256, the samples are made from the FRTP plate, and the flexural strength, flexural modulus and Izod impact value of the FRTP plate are determined as shown in Table 7.
EXAMPLE 16
An FRTP plate is formed in the same manner as that in Example 15 other than using the bundle of carbon fibers "TORAYCA" T300-6K. The flexural strength, flexural modulus and Izod impact value are determined in the same manner as that in Example 12 and the resulted data are shown in Table 7.
In all these Examples 12 to 16, the FRTP plates having high strength, high rigidity and high impact resistance as shown in Table 7.
TABLE 7______________________________________Flexural Flexural Izod impactstrength modulus value(kgf/mm.sup.2) (kgf/mm.sup.2) (kgf.cm/cm.sup.2)______________________________________Ex. 12 37 1310 95Ex. 13 45 2370 42Ex. 14 47 2460 39Ex. 15 31 1300 130Ex. 16 40 2300 41______________________________________
EXAMPLE 17
The strip pieces of glass fibers impregnated with nylon 6 which are obtained in Example 15 and the strip pieces of carbon fibers impregnated with nylon 6 which are obtained in Example 16 are mixed at the ratios of 30, 50 and 70 vol.%, and the mixed strip pieces are distributed in a cavity of a mold and compression molded at 260° C. to form three kinds of FRTP plates with the different volume contents of glass fibers and carbon fibers which have the thickness of 3 mm.
The flexural strength, flexural modulus and Izod impact value of the respective FRTP plates are determined according to ASTM-D-790 and D-256. The resulted data are shown in Table 8. As shown in Table 8, the FRTP plate simultaneously having two or more kinds of excellent mechanical properties can be obtained by combining the different kinds of reinforcing fibers.
TABLE 8______________________________________ Mixing ratio (vol. %)______________________________________Strip pieces of 30 50 70Ex. 15Strip pieces of 70 50 30Ex. 16Flexural strength 39 34 31(kgf/mm.sup.2)Flexural modulus 2000 1700 1400(kgf/mm.sup.2)Izod impact 74 84 110value(kgf.cm/cm.sup.2)______________________________________
Next, various FRTP products according to the present invention are explained with reference to the drawings.
Since the FRTP plates according to the present are excellent quasi-isotropic, and they have high mechanical properties such as flexural strength, flexural modulus and impact resistance and good fittability, various FRTP products having high mechanical properties and in which reinforcing fibers are uniformly distributed can be easily molded even if the FRTP products have complicated shapes.
EXAMPLE 18
The FRTP plates obtained in Example 16 are preheated to a temperature of 260° C. by a hot blast oven, and the preheated FRTP plates 21 are stacked in a cavity 22 of a lower mold 23 as shown in FIG. 6A. An upper mold 24 is closed, and the FRTP plates are molded to an H-type channel 25 as an FRTP product by the compression molding by molds 23 and 24 heated at 250° C. as shown in FIG. 6B. The channel 25 obtained (FIG. 6C) has good quasi-isotropic and high mechanical properties. Even if rivet holes are defined on channel 25, the bearing strength of the portions around the rivet holes can be sufficiently high.
EXAMPLE 19
The FRTP plates obtained in Example 16 are preheated to a temperature of 280° C. by a hot blast oven, and the preheated FRTP plates 31 are stacked in a cavity 32 of a lower mold 33 as shown in FIG. 7A. A piston or rod type upper mold 34 is inserted into the cavity, and the FRTP plates are molded to a pipe joint 35 by the compression molding by molds 33 and 34 heated at 250° C. as shown in FIG. 7B. The pipe joint 35 obtained (FIG. 7C) is used, for example, for the frame of a bicycle.
EXAMPLE 20
The FRTP plate obtained in Example 16 is preheated to a temperature of 280° C. by a hot blast oven, and the preheated FRTP plate 41 is placed between molds 42 and 43 heated at 200° C. as shown in FIG. 8A. Molds 42 and 43 are closed, and the FRTP plate is molded to an upper casing 44 of a camera by stamping molding method as shown in FIG. 8B. The upper casing 44 obtained (FIGS. 8C and 8D) has good quasi-isotropic and high mechanical properties even if it is relatively thin.
EXAMPLE 21
The FRTP plates with appropriate length and width obtained in Example 8 are preheated to a temperature of 280° C., and the preheated FRTP plates 51 are stacked in a pot 52 formed in an upper mold 53 as shown in FIG. 9A. The FRTP plates 51 are pressed by a plunger 56 and transferred into a cavity 55 formed between upper mold 53 and a lower mold heated at 200° C. to mold a head 57 of a golf club by transfer molding as shown in FIG. 9B. The head 57 obtained (FIGS. 9C and 9D) has good quasi-isotropic and high mechanical properties.
EXAMPLE 22
The FRTP plates obtained in Example 8 are preheated at 280° C., and the preheated FRTP plates 61 are stacked in a pot 62 formed in a mold 63 as shown in FIG. 10A. The FRTP plates 61 are pressed by a plunger 64 and transferred into a cavity 65 formed in mold 63 heated at 200° C. to mold a casing 66 of a reel for fishing by transfer molding as shown in FIG. 10B. The casing 66 obtained (FIGS. 10C and 10D) also has good quasi-isotropic and high mechanical properties.
EXAMPLE 23
The FRTP plates obtained in Example 3 are preheated to a temperature of 280° C. by a hot blast oven, and the preheated FRTP plates 71 are stacked and placed between molds 72 and 73 heated at 180° C. as shown in FIG. 11A. The molds 72 and 73 are closed, and the FRTP plates are molded to an oil pan 74 of an engine by stamping molding method as shown in FIG. 11B. The oil pan 74 obtained (FIG. 11C) can have high mechanical properties in any portion thereof.
EXAMPLE 24
The FRTP plates obtained in Example 1 are preheated to a temperature of 280° C. by a hot blast oven, and the preheated FRTP plates 81 are stacked in a pot 82 formed in a mold 83 heated at 180° C. as shown in FIG. 12A. The FRTP plates 81 are pressed by a plunger 84 and transferred into a cavity 85 to mold a base 86 of a door mirror equipment for a vehicle by transfer molding as shown in FIG. 12B. Although the base (FIGS. 12C and 12D) has a relatively complicated shape, the base can be easily molded and the base obtained can have good quasi-isotropic and high mechanical properties.
EXAMPLE 25
The FRTP plates obtained in Example 14 and cut in a circular shape are preheated to a temperature of 400° C. by a hot blast oven, and the preheated FRTP plates 91 are stacked on a lower mold 92 as shown in FIG. 13A. Lower mold 92, upper mold 93 and side molds 94a and 94b heated at350° C. are closed, and the FRTP plates are molded to a wheel 95 for a vehicle by compression molding as shown in FIG. 13B. The wheel obtained (FIG. 13C) has excellent quasi-isotropic and excellent mechanical properties of flexural strength, flexural modulus and impact strength.
EXAMPLE 26
The FRTP plates obtained in Example 15 are preheated to a temperature of 280° C. by a hot blast oven, and the preheated FRTP plates 101 are stacked and placed between molds 102 and 103 heated at 200° C. as shown in FIG. 14A. Molds 102 and 103 are closed to mold a cylinder head cover 104 by stamping molding method as shown in FIG. 14B. The cylinder head cover obtained (FIG. 14C) has good quasi-isotropic and excellent mechanical properties.
Although several concrete FRTP products have been explained in Examples 18 to 26, the FRTP plates according to the present invention can be used for molding other structural FRTP products which require good quasi-isotropic and high mechanical properties.
Although several preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alterations can be made to the particular embodiments shown without materially departing from the novel teachings and advantages of this invention. Accordingly, it is to be understood that all such modifications and alterations are included within the scope of the invention as defined by the following claims.
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A thermoplastic composite plate material having a quasi isotropy comprises a thermoplastic resin having a melt viscosity of 1,000-15,000 poise and strip pieces each constructed of unidirectionally orientated reinforcing fibers and each having the specific dimensions of the thickness, the width, the length and the ratio of the width and the length thereof. The strip pieces are randomly distributed in plane parallel to a surface of the composite plate material. Since the composite plate material has good quasi-isotropic and high mechanical properties such as flexural strength, flexural modulus and impact strength, a composite product having good quasi-isotropic and high mechanical properties can be obtained by using the composite plate materials. Moreover, since the composite plate material has a good fittability, a composite product having a complicated shape can be easily molded.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a device for clamping and rotating the object, comprising two plates to be opened and closed or rotated over synchronously.
2. Description of the Prior Art
FIG. 1 illustrates a device for clamping and rotating the object according to the prior art. As illustrated, the device 10 comprises a first plate 111 , a second plate 113 , two first rods 13 , and a second rod 15 . The first plate 111 is positioned oppositely with the second plate 113 , and a clamping space 12 is provided between the first plate 111 and the second plate 113 .
Two first rods 13 are provided on two ends of the first plate 111 and the second plate 113 respectively, that is, one ends of the first rods 13 are respectively connected to the first plate 111 and the second plate 113 through the first cylinder 171 and second cylinder 173 . Accordingly, the first plate 111 and the second plate 113 can be drove to displace up and down for adjusting the size of clamping space 12 by the first cylinder 171 and the second cylinder 173 , such that the object can be clamped between the first plate 111 and the second plate 113 .
Besides, another end of the first rod 13 is connected to two ends of a second rod 15 through a transmission belt 19 , accordingly, the first plate 111 and the second plate 113 can be drove to rotate by the first rod 13 since the second rod 15 is rotated. In other words, the first plate 111 and the second plate 113 of the device 10 can be used for clamping and rotating the object.
However, during the device 10 is clamping and rotating the object, the cylinders 171 and 173 thereof may telescoped asynchronously; therefore, as two first cylinders 171 telescope asynchronously, two ends of the first plate 111 will be with different heights; similarly, as two second cylinders 173 telescope asynchronously, two ends of the second plate 113 will be with different heights. Accordingly, it is inconvenient for use.
Moreover, the first plate 111 may be damaged due to the left first cylinder 171 and the right first cylinder 171 are telescoped asynchronously, that is, the left first cylinder 171 is telescoped faster than the right first cylinder 171 , similarly, the second plate 113 may be damaged due to the left second cylinder 173 and the right second cylinder 173 are telescoped asynchronously.
The gravity also affects the first cylinder 171 and the second cylinder 173 to telescope asynchronously through the first plate 111 and the second plate 113 during the operation process; for example, when the first plate 111 is positioned upper than the first cylinder 171 , the first cylinder 171 will bear the weight of the first plate 111 , such that the first cylinder 171 will extend slower and retract faster; comparatively, when the second plate 113 is positioned lower than the second cylinder 173 , the second cylinder 173 will bear the weight of the second plate 113 , such that the second cylinder 173 will extend faster and retract slower. Therefore, the device 10 will be inconvenient for use due to the first plate 111 and the second plate 113 are displaced asynchronously.
SUMMARY OF THE PRESENT INVENTION
It is, therefore, the main object of the present invention to provide a device for clamping and rotating the object, which comprises two linked units connected with two ends of the first plate and the second plate, the first plate and the second plate being drove by two linked units simultaneously to be displaced up and down synchronously.
It is another object of the present invention to provide a device for clamping and rotating the object, wherein one ends of two first rods are respectively connected to two rotating units, and another ends thereof are respectively connected to a third rod for balancing the rotating angles of two first rods and two rotating units, such that the heights of the first plate and the second plate are kept to be equal.
It is still another object of the present invention to provide a device for clamping and rotating the object, wherein the linked unit comprises a rotating unit and two connecting units, and the rotating unit is connected respectively to the first plate and the second plate through two connecting units. The first plate and the second plate are drove by the rotating units through the connecting units, such that the first plate and the second plate can be displaced up and down synchronously.
It is still another object of the present invention to provide a device for clamping and rotating the object, wherein one ends of two second rods are respectively connected to the first plate and the second plate through the slides, and the first plate and the second plate can be slid along the slides. Another ends of two second rods are connected to a fourth rod, and the first plate and the second plate can be rotated by the fourth rod through the second rod.
It is still another object of the present invention to provide a device for clamping and rotating the object, wherein the second rod is connected to the rotating unit through the cylinder, the rotating unit is rotated by the cylinder to alter the size of the clamping space between the first plate and the second plate for benefiting to clamp the object positioned between the first plate and the second plate.
It is still another object of the present invention to provide a device for clamping and rotating the object, wherein the first rod is positioned within a through hole of the second rod, and the third rod is positioned within a through hole of the fourth rod, such that the first rod and the second rod can be rotated independently, and the third rod and the fourth rod can be rotated independently, besides, the volume of the device can be reduced.
To achieve these and other objects of the present invention, a device for clamping and rotating the object comprises a first plate, a second plate, two linked units, two first rods, two second rods, a third rod, and a fourth rod. The second plate is placed in the opposite position of the first plate, wherein a clamping space is provided between the first plate and the second plate. Each of two linked units comprises a rotating unit and two connecting units, wherein the rotating unit is connected to the first plate and the second plate through connecting units. Two first rods are respectively connected to two rotating units for driving the rotating unit to rotate. Two second rods are respectively connected to two rotating units for driving the first plate and the second plate to rotate through the rotating unit. The third rod is connected to two first rods. The fourth rod is connected to two second rods.
In one embodiment of aforesaid device for clamping and rotating the object, wherein the second rod is connected to the rotating unit through a cylinder, which is used for driving the rotating unit to rotate.
In one embodiment of aforesaid device for clamping and rotating the object, wherein two the first rods are connected to the third rod through a first linked unit respectively, and two the second rods are connected to the fourth rod through a second linked unit respectively.
In one embodiment of aforesaid device for clamping and rotating the object, wherein the third rod is passed through a through hole provided within the fourth rod.
In one embodiment of aforesaid device for clamping and rotating the object, wherein two the first rods are connected to the rotation axles of two the rotating units respectively.
To achieve these and other objects of the present invention, a device for clamping and rotating the object comprises a first plate, a second plate, two linked units, two first rods, two second rods, a third rod, and a fourth rod. The second plate is placed in the opposite position of the first plate, wherein a clamping space is provided between the first plate and the second plate. Each of two linked units comprises a rotating unit and two connecting units, wherein the rotating unit is connected to the first plate and the second plate through the connecting units. Two first rods are respectively connected to two rotating units for driving the rotating unit to rotate. Two second rods are respectively connected to the first plate and the second plate for driving the first plate and the second plate to rotate. The third rod is connected to two first rods. The fourth rod is connected to two second rods.
In one embodiment of aforesaid device for clamping and rotating the object, wherein each of the second rods is connected to the first plate and second plate through at least one slide.
In one embodiment of aforesaid device for clamping and rotating the object, wherein a sliding seat is provided on each end of the first plate and second plate, wherein the first plate and second plate are connected to the slides through the sliding seats.
In one embodiment of aforesaid device for clamping and rotating the object, wherein the third rod is passed through a through hole provided within the fourth rod.
In one embodiment of aforesaid device for clamping and rotating the object, wherein two the first rods are connected to the third rod through a first linked unit respectively, and two the second rods are connected to the fourth rod through a second linked unit respectively.
In one embodiment of aforesaid device for clamping and rotating the object, wherein two the first rods are connected to the rotation axles of each of two the rotating units respectively.
In one embodiment of aforesaid device for clamping and rotating the object, further comprising at least one cylinder used for driving the first rods or the rotating units to rotate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic structural view of a device for clamping and rotating the object, according to the prior art;
FIG. 2 is a schematic structural view of a device for clamping and rotating the object, in accordance with a first embodiment of the present invention;
FIGS. 3A and 3B are schematic sectional views of different parts of the device for clamping and rotating the object in accordance with the first embodiment of the present invention;
FIG. 4 is a schematic structural view of a device for clamping and rotating the object, in accordance with a second embodiment of the present invention;
FIG. 5 is a schematic structural view of a device for clamping and rotating the object, in accordance with a third embodiment of the present invention; and
FIG. 6 is a schematic structural view of a device for clamping and rotating the object, in accordance with a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Please refer to FIG. 2 , a device for clamping and rotating the object in accordance with a first embodiment of the present invention is shown. The device 20 comprises a first plate 211 , a second plate 213 , two first rods 23 , two linked units 24 , two second rods 27 , a third rod 25 , and a fourth rod 29 . The first plate 211 is placed in the opposite position of the second plate 213 , and a clamping space 22 is provided between the first plate 211 and the second plate 213 . The object, such as the stacked web products, can be placed in the clamping space 22 , for being clamped and rotated through the first plate 211 and the second plate 213 .
Two linked units 24 respectively comprise a rotating unit 241 and two connecting units 243 , wherein the rotating unit 241 is connected to the first plate 211 and the second plate 213 respectively through two connecting units 243 . The rotating unit 241 rotates to drive the first plate 211 and the second plate 213 through two connecting units 243 , such that the first plate 211 and the second plate 213 can be displaced up and down synchronously.
Referring to FIG. 3A , the first plate 211 and the second plate 213 are displaced up and down synchronously for enlarging the clamping space 22 between the first plate 211 and the second plate 213 when the rotating unit 241 is rotated with small angle on clockwise direction. On the contrary, the first plate 211 and the second plate 213 are displaced down and up synchronously for reducing the clamping space 22 between the first plate 211 and the second plate 213 when the rotating unit 241 is rotated with small angle on counterclockwise direction. In actual practice, the rotating unit 241 can be as a gear, and the connecting unit 243 comprises the corresponding dentate structure 2433 , such that two connecting units 243 can be drove to alter the size of clamping space 22 between the first plate 211 and the second plate 213 when the gear 241 is rotated, as shown on FIG. 3B .
The first plate 211 and the second plate 213 are connected with the rotating unit 241 through the connecting units 243 and displaced synchronously when the rotating unit 241 is rotated. Besides, the linked unit 24 can be used for balancing the displacement rate between the first plate 211 and the second plate 213 , for example, when the second plate 213 positioned in the lower place is affected by the gravity, the gravity of second plate 213 will be transferred to the first plate 211 through the connecting unit 243 and rotating unit 241 , such that the difference of displacement rate between the first plate 211 and the second plate 213 can be got over due to the gravity effect.
One ends of two first rods 23 are respectively connected to two rotating units 241 . For example, the first rod 23 is connected to the rotation axle of rotating unit 241 , and the rotating unit 241 is drove to rotate for adjusting the spacing between the first plate 211 and the second plate 213 when the first rod 23 is rotated. Another ends of two first rods 23 are respectively connected to the third rod 25 , wherein the third rod 25 can be used for balancing the rotating angle of two first rods 23 and two rotating units 241 . For example, the right first rod 23 is drove to rotate when the left first rod 23 is rotated through the third rod 25 ; one the contrary, the left first rod 23 is drove to rotate when the right first rod is rotated through the third rod 25 . In this embodiment, the first rod 23 is connected to the third rod 25 through the transmission belt, the chain, or the gear, and so on; accordingly, the third rod 25 can be used for balancing the rotating angles of two first rods 23 and two rotating units 241 , such that the height of two ends of the first plate 211 and the second plate 213 can be equal.
One ends of two second rods 27 are respectively connected to two rotating units 241 , first plate 211 , and/or second plate 213 . The first plate 211 and the second plate 213 are drove to rotate by the rotating units 241 . In this embodiment, two second rods 27 are connected to the rotating units 241 through a cylinder 26 respectively for driving the rotating units 241 to rotate, such that the size of clamping space 22 between the first plate 211 and the second plate 213 can be altered. Besides, the first plate 211 and the second plate 213 can be drove to rotate by the second rods 27 through the cylinders 26 and linked units 24 . Certainly, the second rods 27 can be connected to the rotating units 241 respectively through two cylinders 26 , wherein two cylinders 26 are provided on two ends of the rotation axles of rotating units 241 .
Another ends of two second rods 27 are respectively connected to the fourth rod 29 . For example, the second rods 27 can be connected to the fourth rod 29 through the transmission belt, the chain, or the gear, and so on; accordingly, when the fourth rod 29 is rotated, two second rods 27 will be drove to rotate, furthermore, the first plate 211 and the second plate 213 will be drove to rotate by the second rods 27 through the cylinder 26 and linked unit 24 .
In this embodiment, the second rods 27 further comprise a through hole 271 respectively, such that the first rods 23 can respectively pass through the through holes 271 ; furthermore, the diameters of first rods 23 are smaller than the through holes 271 ; therefore, the first rods 23 can be rotated within the through holes 271 ; for example, the first rods 23 and the second rods 27 are with the same rotation axles. As well as, the fourth rod 29 can be with a through hole 291 , such that the third rod 25 can pass through the through hole 291 , wherein the diameter of third rod 25 is also smaller than the through hole 291 , therefore, the third rod 25 can be rotated within the through hole 291 ; for example, the third rod 25 and the fourth rod 29 are with the same rotation axles.
Certainly, the fourth rod 29 can be provided out of the third rod 25 in other embodiment, as shown on FIG. 4 , wherein the device 200 and the device 20 are with the same functions also.
Referring to FIG. 5 , a device for clamping and rotating the object in accordance with a third embodiment of the present invention is shown. The device 30 comprises a first plate 211 , a second plate 213 , two first rods 23 , two linked units 24 , two second rods 27 , a third rod 25 , and a fourth rod 29 .
The first rods 23 are connected to the first plate 211 and the second plate 213 respectively through the linked units 24 , wherein each of the linked units 24 comprises a rotating unit 241 and two connecting units 243 . The first rods 23 are connected to the rotating units 241 , and the rotating units 241 are respectively connected to the first plate 211 and the second plate 213 through two connecting units 243 . The first plate 211 and the second plate 213 are drove to displace up and down for altering the size of clamping space 22 between the first plate 211 and the second plate 213 by the rotating units 241 through the connecting units 243 , wherein the rotating units 241 are drove to rotate by the first rods 23 ; therefore, the object, such as the stacked web products, positioned between the first plate 211 and the second plate 213 , can be clamped accordingly.
In this embodiment, the device 30 comprises at least one cylinder 36 , wherein the cylinder 36 can be used to drive the first rods 23 and/or the rotating units 241 to rotate with a small angle for adjusting the size of clamping space 22 . Two first rods 23 are respectively connected to the third rod 25 through a first linked unit 381 , wherein the first linked unit 381 can be as a gear, a transmission belt, or a chain, and so on. In other embodiment, the first rods 23 can be directly connected to the third rods 25 .
Two first rods 23 are respectively connected to the third rod 25 through the first linked unit 381 ; accordingly, when one of the first rod 23 is rotated, another one of the first rod 23 will be drove to rotate through the first linked unit 381 and the third rod 25 , such that two first rods 23 and two rotating units 241 will be with the same rotating angles, and the heights of two ends of the first plate 211 and the second plate 213 will be equal.
Two second rods 27 are respectively connected to the first plate 211 and the second plate 213 , and used to drive to rotate the first plate 211 and the second plate 213 ; for example, two second rods 27 can be respectively connected to the first plate 211 and the second plate 213 through a slide 331 ; furthermore, the first plate 211 and the second plate 213 can be displaced along the slide 331 . In this embodiment, two ends of the first plate 211 and the second plate 213 are respectively with a sliding seat 333 provided; therefore, the first plate 211 and the second plate 213 can be connected with the sliding seats 333 through the slides 331 , such that the first plate 211 and the second plate 213 can be drove to displace along the slides 331 when the first rods 23 and/or the rotating units 241 are rotated.
The second rods 27 are rotated to drive the slides 331 and/or sliding seats 333 to rotate, such that the first plate 211 and the second plate 213 can be rotated accordingly, and the object, such as the stacked web products, positioned between the first plate 211 and the second plate 213 , can be rotated as well. Two second rods 27 are respectively connected to the fourth rod 29 through a second linked unit 383 , wherein the second linked unit 383 can be as a gear, a transmission belt, or a chain, and so on. In other embodiment, the second rods 27 can be directly connected to the fourth rod 29 . Therefore, the fourth rod 29 can be rotated to drive the second rods 27 to rotate, and the first plate 211 and the second plate 213 can be rotated accordingly.
In this embodiment, the second rods 27 comprise through holes 271 respectively, and the first rods 23 are provided within the through holes 271 , such that the first rods 23 can be rotated within the through holes 271 . The fourth rod 29 comprises a through hole 291 , and the third rod 25 is provided within the through hole 291 , such that the third rod 25 can be rotated within the through hole 291 . Accordingly, the volume of the device 30 can be efficiently reduced due to the foresaid embodiment, as shown on FIG. 5 .
Certainly, the third rod 25 can also be provided out of the fourth rod 29 , as shown on FIG. 6 , wherein the device 300 and device 30 are with the same functions also.
Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
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A device, used for clamping and rotating the object, includes two first rods, one ends of which are respectively connected to one ends of the first plate and the second plate through a linked unit; another ends of the first rods are connected to the third rod that is used for balancing the rotating angles of the first rod and two linked units, such that the heights of two ends of the first rods and the second rods can be kept in step. Two second rods are connected to the first plate and the second plate respectively, as well as, another ends of second rods are connected to the fourth rod respectively. Accordingly, the fourth rod can be rotated to drive the second rod, such that the first plate and the second plate can be rotated. Therefore, due to two plates are used for clamping and rotating synchronously, users can take the advantages while the device is used.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application relates claims priority to and the benefit of co-pending United Kingdom Patent Application No. 0811205.4 filed on 19 Jun. 2008, the full disclosure of which is hereby incorporated fay reference.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates to hydraulic intensifiers.
[0004] 2. Description of Related Art
[0005] Hydraulic intensifiers are devices that generate high hydraulic pressure from a low pressure source. When employed in subsea wells such as hydrocarbon production or injection wells, they provide a source of high pressure hydraulic fluid for the operation of hydraulically actuated devices, such as valves and flow control chokes. Such wells are, typically, supplied with low pressure hydraulic fluid via an umbilical, which can be in excess of 100 Km in length. The supply of high pressure fluid via the umbilical is not favoured by well operators, as a high pressure feed within the umbilical, needing a much greater wall thickness than usual, results in much greater umbilical and handling costs. Intensifiers use relatively large cross-sectional area pistons, operating at low pressure, to actuate small cross-sectional area pistons, to generate high pressures, thus utilising the mechanical advantage of the ratios of the piston cross-sectional areas to ‘intensify’ the pressure.
[0006] Typically, two sets of pistons are utilised which operate alternately to sustain a continuous flow of fluid. The alternate operation of the piston sets is controlled by a complicated arrangement of valves and springs and since these and the piston sets are integrated into one assembly, current hydraulic intensifiers are complicated devices, which are difficult to manufacture and thus of high cost. Furthermore, they are heavy devices, typically 37 Kg, and are prone to a multiplicity of problems which include failure of ‘slipper’ seals and changeover valves, sensitivity to contamination and a tendency to ‘lock-up’ due to pressure in their return lines. Repair requires the complete removal and strip down of the assembly which is also expensive, and new designs require full approval testing before they can be employed.
[0007] GB-A-2 275 969 discloses a hydraulic intensifier comprising two sets of high and low pressure pistons for the compression of low pressure liquid, the piston sets being coupled together by the slider of a pilot valve so as to act in mutual opposition, the low pressure pistons of the piston sets being driven by low pressure liquid supplied by way of a changeover valve and the changeover valve being changed over at the end of each stroke of the pilot valve to reverse the motion of the piston sets, the changeover valve being effective to maintain a supply of low pressure liquid to drive the piston sets throughout the stroke of the pilot valve.
SUMMARY
[0008] Disclosed herein is a hydraulic intensifier having a piston and cylinder assembly with a first piston in a chamber of a low pressure cylinder and a second piston in a chamber of a high pressure cylinder, the first and second pistons being coupled together and the first piston having a larger cross-sectional area than the second piston, a high pressure output coupled to the chamber of the high pressure cylinder, means for supplying low pressure hydraulic fluid to the chamber of the low pressure cylinder, an electrically operated directional control valve for controlling the supply of low pressure hydraulic fluid to the chamber of the low pressure cylinder, and an electronic device operatively connected to the directional control valve.
[0009] The hydraulic intensifier may further include a second piston and cylinder assembly, rite high pressure output being coupled to the chamber of the high pressure cylinder of the second piston and cylinder assembly; and a second directional control valve for controlling the supply of low pressure fluid from the supplying means to the chamber of the low pressure cylinder of the second piston and cylinder assembly, the electronic device connected to the directional control valves to supply low pressure fluid alternately to the chambers of the low pressure cylinders of the first and second piston and cylinder assemblies.
[0010] Another embodiment of a hydraulic intensifier includes a first piston and cylinder assembly having a first piston in a chamber of a low pressure cylinder and a second piston in a chamber of a high pressure cylinder, the first and second pistons being coupled together and the first piston having a larger cross-sectional area than the second piston, a second piston and cylinder assembly, a high pressure output coupled to the chambers of the high pressure cylinders of the first and second piston and cylinder assemblies, a low pressure hydraulic fluid supply to the chambers of the low pressure cylinders of the first and second piston and cylinder assemblies, first and second electrically operated directional control valves in fluid communication with the supply of low pressure hydraulic fluid and the chambers of the low pressure cylinders of the first and second piston and cylinder assemblies respectively, and an electronic device operatively coupled to the directional control valves to selectively energize the control valves to thereby supply low pressure hydraulic fluid alternately to the chambers of said low pressure cylinders.
[0011] Low pressure hydraulic fluid could he supplied to the chambers of the high pressure cylinders via respective ones of first and/or second check valves, said chambers of the high, pressure cylinders being coupled with said high pressure output via respective ones of third and fourth check valves.
[0012] The hydraulic intensifier could include a pressure sensing device coupled to said electronic means for sensing pressure of hydraulic fluid at said high pressure output and causing the or each directional control valve not to supply hydraulic fluid to the chamber or chambers of the low pressure cylinder or cylinders in response to the sensed pressure being at a required value. The electronic device could comprise a bistable device. A hydraulic accumulator can be optionally included that is coupled with the high pressure output.
[0013] A hydraulic intensifier could be one for use in a subsea well. In a subsea application electrical control could be provided via a subsea electronics module for a subsea well and/or the directional flow control could be provided by a directional control valve of a subsea control module for a subsea well.
[0014] Also disclosed herein is a method of producing high pressure hydraulic fluid. In one example the method includes providing a piston and cylinder assembly having a first piston in a chamber of low pressure cylinder and a second piston in a chamber of a high pressure cylinder, the first and second pistons being coupled together, the first piston having a larger cross-sectional area than the second piston and there being a high pressure output coupled to the chamber of the high pressure cylinder, supplying low pressure hydraulic fluid to the chamber of the low pressure cylinder, and controlling the supply of low pressure hydraulic fluid to the chamber of the low pressure cylinder by selectively energizing the directional control valve.
[0015] The method can also include providing a second piston and cylinder assembly, the high pressure output being coupled to the chamber of the high pressure cylinder of the second piston and cylinder assembly, providing a second directional control valve for controlling supply of low pressure fluid to the chamber of the low pressure cylinder of the second piston and cylinder assembly, and using an electronic device to selectively energize the directional control valves to supply low pressure fluid alternately to the chambers of the low pressure cylinders of the first and second piston and cylinder assemblies.
[0016] The present disclosure, in one example, enables a modular hydraulic intensifier which utilises standard approved directional control valves (DCVs) which are controlled electronically, in conjunction with piston sets sealed with proven standard approved seals. By being modular, such an intensifier can be serviced by the replacement of individual components, most of which are standard devices which will already be held as spares for the rest of the well control system.
DESCRIPTION OF FIGURES
[0017] FIG. 1 schematically illustrates an example of a hydraulic intensifier in accordance with the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
[0019] An example of a hydraulic intensifier for a subsea hydrocarbon extraction or injection well is provided in FIG. 1 . Two piston and cylinder assemblies 1 and 2 , which may be identical, are shown in sectioned view. An associated hydraulic circuit is shown schematically. Each piston assembly has a large cross-sectional area piston 3 , 3 ′ depending from one side and a smaller cross-sectional area piston 7 , 7 ′ depending from its opposite end. The larger cross-sectional area piston 3 , 3 ′ is shown disposed in the chamber 4 , 4 ′ of a low pressure cylinder. Seals 5 , 5 ′ and 6 , 6 ′ are shown between the piston 3 , 3 ′ and chamber 4 , 4 ′ of low pressure cylinder. The smaller cross-sectional area piston 7 , 7 ′ is shown in high pressure cylinder chamber 8 , 8 ′ with seal 9 , 9 ′ therebetween. The chamber 4 , 4 ′ of each low pressure cylinder includes a buffer 10 , 10 ′; that can be manufactured from a resilient, hydraulic fluid resistant material, to minimise the impact of a fast-returning piston.
[0020] The operation of each of the piston assemblies 1 and 2 , may be controlled, alternately, by respective ones of standard solenoid-operated directional control valves (DCVs) 11 and 12 . A low pressure (LP) supply 13 , typically via the well umbilical, is shown providing hydraulic fluid to the DCVs 11 and 12 . The solenoids of the DCVs 11 and 12 are electrically energised alternately from a dc power source switched by an electronic device 14 such as a multivibrator, that can be bistable. Each DCV 11 and 12 is coupled to the chamber 4 , or 4 ′ of the respective low pressure cylinder via a respective restrictor 15 or 16 . Source 13 is shown connected to the chambers 8 , 8 ′ of the high pressure cylinders via check valves 17 and 18 respectively. Also, each of the chambers 8 , 8 ′ is shown connected to a high pressure (BP) intensifier output line 19 via check valves 20 and 21 respectively, reference numeral 22 designating a hydraulic accumulator connected with line 19 and reference numeral 23 designating a pressure switch connected to device 14 . Reference numeral 24 designates a return line for excess fluid.
[0021] An example of a mode of operation of the intensifier is as follows. After installation, low pressure hydraulic fluid from the source 13 primes the system and additionally provides, via check valves 17 and 18 respectively, a continuous supply of hydraulic fluid to the chambers 8 , 8 ′ of the high pressure cylinders. In the condition of the assemblies 1 and 2 and DCVs 11 and 12 as shown, the solenoid of DCV 11 has been de-energised and that of DCV 12 has been energised so that piston 3 ′ has been driven by low pressure fluid that entered chamber 4 ′. Then, the solenoid of DCV 11 is energised by dc power, switched by the device 14 , which allows low pressure hydraulic fluid to operate the piston 3 in the chamber 4 of the low pressure cylinder of the piston/cylinder assembly 1 , the solenoid of DCV 12 being de-energised. The rate of movement of the piston 3 may be controlled by an optional hydraulic restrictor 15 . The resultant operation of piston 7 forces hydraulic fluid from the chamber 8 of the high pressure cylinder of assembly 1 at high pressure (HP), via check valve 20 , to the intensifier output line 19 and into hydraulic accumulator 22 . The check valve 17 will close to isolate the generated high pressure from the low pressure source.
[0022] The piston 7 ′ in the piston/cylinder assembly 2 will be forced downwards, with the hydraulic fluid transferring from below the piston 3 ′ in the chamber 4 ′ to above the piston 3 ′ in the chamber 4 ′ via the DCV 12 . When de-energized, the DCV 12 directs flow received from the hydraulic restrictor 16 and along a path through the circuit as indicated by arrow 25 . At the same time, the chamber 8 ′ of the high pressure cylinder of assembly 2 is filled by the low pressure source 13 via the check valve 18 . The transfer of fluid from beneath to above the piston 3 ′ within the chamber 4 ′, in the flow direction 25 , minimises the consumption of hydraulic fluid. Optionally, as the piston 3 ′ downstrokes, fluid in the chamber 4 ′ beneath the piston 3 ′ can be routed to chamber 8 ′. Yet further optionally, as either of pistons 3 , 3 ′ is being urged upwards. fluid in die respective chamber 4 , 4 ′ above the piston 3 , 3 ′ being raised can be routed to the other chamber 4 , 4 ′ of the low pressure cylinder above the respective piston 3 , 3 ′.
[0023] At a pre-set time, the electronic device 14 , will change state, thus removing dc power from the solenoid of DCV 11 and applying dc power to the solenoid of DCV 12 . When energized, the DCV 12 directs low pressure fluid from the source 13 through the restrictor 16 and into the chamber 4 ′ below the piston 3 ′. Although pressure in chambers 4 ′ and 8 ′ is initially substantially the same, the larger surface area of piston 3 ′ creates an upward resultant force pushing the piston 7 ′ into the chamber 8 ′ to thereby form high pressure fluid in the piston/cylinder assembly 2 . The high pressure fluid is pumped via check valve 21 to the intensifier output line 19 and to the accumulator 22 . Thus, the DCVs 11 and 12 operate alternately, providing alternate pumping by the piston/cylinder assemblies 1 and 2 of high pressure fluid to the accumulator 22 . Excess fluid from the process is exhausted via return line 24 as for existing intensifiers. The pumping process continues until the required high pressure is achieved at the accumulator 22 as sensed by pressure switch 23 , which then switches off the dc power to the DCV solenoids via device 14 .
[0024] In practice, the device 14 may be dispensed with in atypical well installation, since control of the solenoids of the DCVs can be effected by the subsea control module (SCM) of the well. This module already houses DCVs and a subsea electronics module (SEM) to electronically control them, typically by an electronic processor driving power amplifiers to operate the DCV solenoids. It would therefore be a relatively simple addition to the SEM to incorporate the functions of the device 14 within the software of the SCM processor, and the necessary solenoid power drivers to the SCM Also, the intensifier DCVs could be housed in the SCM. Furthermore, the hydraulic accumulator 22 may not be necessary for some installations.
[0025] Although the above example of the invention uses a dual piston/cylinder arrangement, the intensifier could use a single piston/cylinder arrangement. However the twin arrangement described provides redundancy in the event of a failure and is therefore generally the preferred option.
[0026] Preferably, the DCVs are standard-approved devices, a main advantage of using the same to control the intensifier being that they would not require an expensive test for type approval in a subsea well environment.
[0027] Other advantages which are enabled by the invention are: modularity, which, permits cost-effective repair; only two basic moving parts compared to existing designs that use a multiplicity of moving parts to mechanically provide the fluid switching sequences to operate the hydraulic pistons; cheaper manufacture as only two ‘special’ parts (piston/cylinder assemblies) are required; and the potential of using existing facilities (e.g. spare DCVs and/or processing power) within a SCM to operate the pistons.
[0028] The improvements described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While presently preferred embodiments have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.
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A hydraulic intensifier with a piston and cylinder assembly ( 1 ) having a first piston ( 3 ) in a chamber ( 4 ) of low pressure cylinder and a second piston ( 7 ) in a chamber ( 8 ) of a high pressure cylinder. The first and second pistons are coupled together and the first piston has a larger cross-sectional area than the second piston. A high pressure output ( 19 ) is coupled to the chamber of the high pressure cylinder, there being; means ( 13 ) for supplying low pressure hydraulic fluid to the chamber of the low pressure cylinder; an electrically operated directional control valve ( 11 ) for controlling the supply of low pressure hydraulic fluid to the chamber of the low pressure cylinder; and electronic means ( 14 ) for controlling operation of the directional control valve.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of a U.S. patent application Ser. No. 12/753,368 filed on Apr. 2, 2010, which is a divisional of U.S. application Ser. No. 11/604,390 filed on Nov. 27, 2006, which is a continuation-in-part of U.S. application Ser. No. 10/048,590 filed on Feb. 1, 2002, now abandoned, which is a 35 U.S.C. §371 national phase of PCT/IT01/00283 filed on Jun. 1, 2001, which claims priority to and the benefit of Italian Application No. RM2000A000323 filed on Jun. 14, 2000, the contents of each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a health food/dietary supplement comprising as its characterising ingredients an alkanoyl L-carnitine selected from the group consisting of isovaleryl L-carnitine and propionyl L-carnitine or their pharmacologically acceptable salts or mixtures of the same and a monosaccharide pentose, particularly ribose or its phosphorylated analogues.
It has been found that the above-mentioned composition is extremely effective in exerting a potent stimulation of muscular energy metabolism, and can thus be profitably used in the prevention of myocardial insufficiency and in post-infarct conditions, as well as in the course of prolonged muscular effort during physical and sporting exercises, owing to the unexpected synergistic effect exerted by its components.
Isovaleryl L-carnitine, a natural component of the pool of carnitines, presents specific activity at lysosomal level and on the cytosolic movements of calcium. It is therefore capable of intervening in proteolytic processes such as occur during intense, prolonged effort and of protecting a number of organs, such as the liver, against the action of toxic substances. Propionyl L-carnitine exerts an intense antioxidant effect and is particularly effective in enhancing the peripheral circulation and cardiac functional capacity.
Moreover, muscular carnitine transferase possesses a greater affinity for propionyl L-carnitine than for L-carnitine, and consequently propionyl L-carnitine possesses a higher degree of specificity for cardiac and skeletal muscle. In addition, propionyl L-carnitine transferase, transporting the propionyl group, increases the uptake of this component by the muscle cells, which may be of particular importance for energy purposes, in that the propionate can be used by the mitochondria as an anapleurotic substrate and provide energy in the absence of oxygen.
Equally well known are the metabolic effects of ribose. Ribose is a monosaccharide pentose which is important in the body for the synthesis of nucleotides and other metabolic products. It is formed by conversion of glucose via the pentose phosphates. In the presence of a ribokinase ribose is phosphorylated to ribose-5-phosphate which, through the production of 5-phosphoribosyl-1-pyrophosphate (PRPP), can be used for the synthesis of nucleotides necessary for the production of ATP. PRPP, in addition to intervening in the production of ATP, is also important for the synthesis of nucleotides such as adenine and hypoxanthine and of ribonucleotides and deoxyribonucleotides.
It has now been found surprisingly that a composition comprising a combination of the following as its characterizing components:
(a) an alkanoyl L-carnitine selected from the group comprising isovaleryl L-carnitine, propionyl L-carnitine or their pharmacologically acceptable salts or mixtures of the same; and
(b) ribose or one of its phosphorylated derivatives thereof,
constitutes an effective health food/dietary supplement for the prevention of states of myocardial or skeletal muscle dysfunction related to conditions of anoxia or insufficient energy supply as occurring in coronary or post-infarct disorders or during prolonged physical activity and muscle fatigue, owing to the potent and unexpected synergistic effect exerted by its components.
The weight-to-weight ratios of the above-mentioned components (a):(b) range from 1:1 to 1:10.
The dietary supplement according to the present invention may additionally contain
(c) a “carnitine” selected from the group comprising L-carnitine, acetyl L-carnitine, butyryl L-carnitine and valeryl L-carnitine, or their pharmacologically acceptable salts or mixtures of the same.
The weight-to-weight ratios of the above-mentioned components (a):(b):(c) range from 1:1:1 to 1:10:2.
The surprising synergistic effect achieved with the combination of “carnitines” (term denoting collectively both L-carnitine and the alkanoyl L-carnitines), particularly isovaleryl L-carnitine and/or propionyl L-carnitine, and ribose, has been demonstrated by several pharmacological tests (some of which are described here below) chosen in such a way as to prove strongly predictive for the purposes of the practical use of this composition in the preventive/nutritional/dietetic field.
In particular, this unexpected synergistic effect on the increase in energy capabilities at both cardiac and muscular level exerted by the combination according to the present invention enables it to be used in the prevention of both myocardial insufficiency and of muscle fatigue such as occur in cases of myocardial ischemia or in the course of intense muscular effort due to prolonged physical exercise or sporting activity.
DETAILED DESCRIPTION OF THE INVENTION
Test of ATP Concentrations in Heart Subjected to Anoxia
In this test the technique adopted was the one using papillary muscle of rabbit heart perfused and subjected to anoxia which, as is known, leads to an impoverishment of its ATP energy reserves. With this test, the aim was to observe whether or not preventive treatment with isovaleryl L-carnitine, with propionyl L-carnitine, with a carnitine combination or with ribose, or with a combination of these was capable of protecting cardiac muscle against the loss of ATP induced by anoxia.
In this test, a batch of New Zealand rabbits was used, subdivided into different groups which were injected intravenously every day for three consecutive days with isovaleryl L-carnitine alone (100 mg/kg), propionyl L-carnitine alone (100 mg/kg) or a carnitine combination consisting of propionyl L-carnitine (25 mg/kg), acetyl L-carnitine (25 mg/kg), L-carnitine (25 mg/kg), and isovaleryl L-carnitine (25 mg/kg) or with ribose alone (100 mg/kg), or ribose combined with the above-mentioned “carnitines”.
At the end of the third day of treatment, all the animals were sacrificed and their hearts excised. Sections of papillary muscle measuring 1 mm in diameter and 4-5 mm in thickness were isolated from the excised hearts. The isolated papillary muscle was perfused in a thermostatic bath with a saturated 100% O 2 solution.
The anoxic state was obtained by introducing 100% N 2 instead of O 2 into the bath. For the measurement of the ATP concentrations in the papillary muscle the method described by Strehler was adopted (Strehler B. L. Methods in Enzymology 111 N.Y. Acad. Press., 879, 1957).
The analysis was carried out on tissue samples maintained in conditions of perfusion with oxygen for 90 minutes and after a period of anoxia of the same duration.
The results of this test, presented in Table 1, indicate that propionyl L-carnitine, isovaleryl L-carnitine, the carnitine combination and ribose are individually capable of partly protecting the ATP present in papillary muscle against anoxia, but that it was only with the combination of propionyl L-carnitine or isovaleryl L-carnitine plus ribose or with the combination of the carnitine combination plus ribose that complete protection against the anoxia-induced reduction in ATP could be obtained, thus demonstrating the potent synergistic effect exerted by the components of the combination.
TABLE 1
Test of ATP concentrations in papillary muscle of
heart subjected to hypoxia
ATP concentration (mol/g tissue)
Treatment
Before hypoxia
After hypoxia
Controls
1.60 ± 0.55
0.41 ± 0.055
Isovaleryl L-carnitine
1.50 ± 0.60
0.55 ± 0.65
Propionyl L-carnitine
1.64 ± 0.79
0.60 ± 0.040
Carnitine combination
1.55 ± 0.50
0.62 ± 0.060
Ribose
1.62 ± 0.39
0.55 ± 0.075
Isovaleryl L-carnitine + ribose
1.50 ± 0.25
1.15 ± 0.055
Propionyl L-carnitine + ribose
1.61 ± 0.45
1.25 ± 0.35
Carnitine combination + ribose
1.65 ± 0.60
1.16 ± 0.30
Experimental Myocardial Anoxia Test
Adopting the technique described by Selych (Selych et al., Angiology, 11, 398, 1960) and modified by Clark (Clark C., J. Pharmacol. Methods, 3, 357, 1980), these tests were used to evaluate the protective activity of isovaleryl L-carnitine, propionyl L-carnitine, carnitine combination, ribose and various combinations of the same against ventricular arrhythmias induced by left coronary ligation in the rat.
Coronary occlusion and the resulting myocardial anoxia lead, after 5-8 minutes, to the onset of arrhythmias. In these tests, ventricular ectopic contractions were counted for a period of 30 minutes after ligation both in control rats and in rats that had received slow injections into the left ventricle, 15 minutes before ligation, of a solution containing isovaleryl L-carnitine alone (100 mg/kg), propionyl L-carnitine alone (100 mg/kg), or carnitine combination alone consisting of propionyl L-carnitine (25 mg/kg), acetyl L-carnitine (25 mg/kg) and isovaleryl L-carnitine (25 mg/kg) or ribose alone (100 mg/kg), or a combination of ribose plus isovaleryl L-carnitine or propionyl L-carnitine or a combination of ribose plus carnitine combination at the doses described above.
The results of this test (Table 2) indicate that, whereas isovaleryl L-carnitine alone or propionyl L-carnitine alone or carnitine combination alone or ribose alone produce only slight reductions in the number of ectopic contractions compared to controls, such contractions are reduced almost to the extent of disappearing altogether when ribose is injected in combination with isovaleryl L-carnitine, or propionyl L-carnitine, or carnitine combination, thus demonstrating the potent and unexpected synergistic effect exerted by the combination according to the present invention.
TABLE 2
Test of arrhythmia induced by myocardial anoxia
N. of
Start of
ectopic contractions
arrhythmias
during 30 minutes after
Treatment
after (mins)
ligation
Controls
5-7
989 ± 96
Isovaleryl L-carnitine
5-7
860 ± 75
Propionyl L-carnitine
5-8
830 ± 86
Carnitine combination
5-8
810 ± 99
Ribose
5-7
855 ± 110
Isovaleryl L-carnitine + ribose
6-7
270 ± 95
Propionyl L-carnitine + ribose
6-8
230 ± 112
Carnitine combination + ribose
6-8
207 ± 93
Some non-limiting examples of compositions according to the present invention are given herein below:
Lozenges, capsules, tablets
1)
Propionyl L-carnitine
500
mg
Ribose
500
mg
2)
Isovaleryl L-carnitine
500
mg
Ribose
500
mg
3)
Propionyl L-carnitine
125
mg
Acetyl L-carnitine
125
mg
L-carnitine
125
mg
Isovaleryl L-carnitine
125
mg
Ribose
500
mg
Granulates or vials
4)
Propionyl L-carnitine
1
g
Ribose
1
g
5)
Isovaleryl L-carnitine
1
g
Ribose
1
g
6)
Propionyl L-carnitine
1
g
Ribose
2.5
g
7)
Propionyl L-carnitine
250
mg
Acetyl L-carnitine
250
mg
Isovaleryl L-carnitine
250
mg
L-carnitine
250
mg
Ribose
2.5
g
8)
Propionyl L-carnitine
250
mg
Acetyl L-carnitine
250
mg
Isovaleryl L-carnitine
250
mg
L-carnitine
250
mg
Ribose
2
g
Ribonucleic acid
100
mg
Deoxyribonucleic acid
100
mg
9)
Propionyl L-carnitine
250
mg
Acetyl L-carnitine
250
mg
Isovaleryl L-carnitine
250
mg
L-carnitine
250
mg
Ribose
2
g
L-glutamine
100
mg
L-alanine
100
mg
L-arginine
100
mg
L-glicine
100
mg
L-histidine
100
mg
L-isoleucine
100
mg
L-phenylalanine
50
mg
L-threonine
50
mg
L-serine
100
mg
10)
Propionyl L-carnitine
250
mg
Acetyl L-carnitine
250
mg
Isovaleryl L-carnitine
250
mg
L-carnitine
250
mg
Ribose
1
g
Destrose
0.5
g
Fructose
0.5
g
Maltose
0.5
g
11)
Propionyl L-carnitine
250
mg
Acetyl L-carnitine
250
mg
Isovaleryl L-carnitine
250
mg
L-carnitine
250
mg
Ribose
1
g
Glucose-1,6-diphosphate
200
mg
Fructose-1,6-diphosphate
200
mg
Galactose-1,6-phosphate
200
mg
Glycerol-3-phosphate
200
mg
Phosphenylpyruvate
100
mg
Thiamine pyrophosphate
5
mg
Pyridoxal-5-phosphate
5
mg
Magnesium stearate
2
mg
12)
Propionyl L-carnitine
250
mg
Acetil L-carnitine
250
mg
Isovaleryl L-carnitine
250
mg
L-carnitine
250
mg
Ribose
1
g
Vit. A
1250
U.I.
Vit. B 1
0.5
mg
Vit. B 6
30
mg
Vit. C
50
mg
Vit. E
5
mg
Nicotinammide
25
mg
Vit. B 12
100
mcg
Vit. D
100
U.I.
Pantothenic acid
30
mg
Magnesium glycinate
5
mg
Manganese
1
mg
L-Selenomethionine
50
mcg
Molybdenum
10
mcg
Zinc
1
mg
What is meant by a pharmacologically acceptable salt of the various carnitines mentioned in the present invention, is, in addition to the respective inner salts, any salt of these with an acid which does not give rise to unwanted toxic or side effects. These acids are well known to pharmacologists and to experts in pharmaceutical technology.
Non-limiting examples of such salts are the following: chloride; bromide; iodide; aspartate, acid aspartate; citrate, acid citrate; tartrate; phosphate, acid phosphate; fumarate, acid fumarate; glycerophosphate; glucose phosphate; lactate; maleate, acid maleate; mucate; orotate; oxalate, acid oxalate; sulphate, acid sulphate; trichloroacetate; trifluoroacetate and methane sulphonate.
Among these salts, isovaleryl L-carnitine acid fumarate (U.S. Pat. No. 5,227,518) is particularly preferred.
A list of FDA-approved pharmacologically acceptable acids is given in Int. J. Pharm., 33, 1986, 201-217, the latter publication being incorporated in the present specification by reference.
The supplement of the invention may further comprise vitamins, coenzymes, mineral substances, aminoacids and antioxidants. The supplement may be manufactured in the form of tablets, lozenges, capsules, pills, granulates, syrups, vials or drops.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalents arrangements included within the spirit and scope of the appended claims.
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A method for treating myocardial or skeletal muscle anoxia which occurs in coronary or post-infarct disorders or during prolonged physical activity and muscle fatigue. This method comprises the administration of a combination composition comprising (a) an alkanoyl L-carnitine selected from the group consisting of isovaleryl L-carnitine, propionyl L-carnitine or the pharmacologically acceptable salts thereof or mixtures thereof; and (b) ribose or a phosphate derivative thereof.
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TECHNICAL FIELD
The present invention relates generally to napkin dispensers and in a preferred embodiment to a gravity feed countertop mounted napkin dispenser having a base secured to a countertop with a quick release mounting bracket.
BACKGROUND ART
Dispensers for napkins including inter-folded napkins are well known in the art. Typically such dispensers are spring-loaded dispensers as is shown, for example, in the U.S. Pat. No. 4,838,454 to Salzmann et al. This class of dispensers are typically placed on a countertop. There is shown in the '454 patent a napkin dispenser including a drawer which slides in and out of the housing and a push plate which also slides in the housing and is spring-biased to push the napkins forward. A pair of locks on the rear of the drawer in the preferred napkin dispenser pushes the plate forward when the drawer is open but pivot to release the push plate when the drawer is closed so the napkins are not pressed too tightly, even if napkins are overloaded in the drawer when it is open.
U.S. Pat. No. 4,679,703 to De Luca discloses a napkin dispenser configured to reduce bunching at the dispensing opening in the napkin dispenser. A pair of pressure relief rods are provided along the upper and lower portions of the dispenser face plate to relieve pressure between the face plate and the center portion of the napkin stack.
U.S. Pat. No. 4,343,415 to Radek shows a napkin dispenser designed for disposition on a restaurant table or counter housing a stack of paper napkins. The dispenser is in the form of a parallelepiped with a top axis opening for loading and removing napkins. The opening is generally rectangular or may taper slightly from one end to the other. A salient feature is that the edges of the opening extend outwardly providing a relatively narrow peripheral arcuate flange or lip around the opening, the effect of which is to lead a napkin gently outwardly without likelihood of damage to the exiting napkins.
U.S. Pat. No. 4,311,252 to Hope, Jr. et al. discloses a large capacity elevator type napkin dispenser including an elongated supporting structure or cage composed of series of spaced rod-like vertical supports. A stack of folded napkins is supported on a pressure plate that is mounted on a carriage adapted to slide vertically within the cage, whereas U.S. Pat. No. 4,094,442, also to Radek discloses a napkin dispenser provided with an aperture which is generally rectangular except for a concavely arcuate edge on one side from which the napkins are normally extracted. Two opposed sides of the opening normal to the arcuate edge are provided with a pair of relatively narrow spring-biased leaves resiliently extendable into the container to facilitate loading, the free edges of the leaves being longitudinally gently oblique and widening to the aforesaid arcuate edge. Each of the leaves has a longitudinal outwardly turned lip and the exposed corners of the leaves are rounded. The features are reported to contribute towards a convenient extraction of a napkin without damage.
As will be appreciated from the foregoing, spring-biased dispensers are prone to overfilling and malfunction and may damage product if the dispensers are misused. Gravity feed dispensers are simpler and less subject to malfunction; however they are more difficult to conveniently locate in establishments which require countertop access to the napkins.
SUMMARY OF INVENTION
There is provided generally in accordance with the invention a countertop mounting base and bracket for releasably securing a napkin dispenser attached to the base. The mounting system includes a base having a generally planar upper surface and a sidewall extending downwardly therefrom to define a hollow cavity and also defining a stepped locking recess having an upper portion with a first recess width and a lower portion with a second recess width where the upper locking recess width is smaller than the lower locking recess width. The base is also provided with a plurality of locking projections in the hollow cavity having locking shoulders thereon each of which has a characteristic locking shoulder width. The base cooperates with a mounting bracket provided with means for attaching the bracket to a countertop. The bracket has a raised central locking surface provided with a moveable tongue adapted to flex with respect to the locking surface from a locking position to a release position. The tongue is provided with a stepped outer profile defining an outer width which is less than equal to the upper recess width of the base. The tongue also has a locking width which is greater than the upper recess width of the base, the locking surface of the mounting bracket being further provided with a plurality of locking slots with open portions having widths at least as great as a corresponding characteristic width of a locking shoulder of a corresponding locking projection of the base. The locking slots of the locking surface also have elongated narrow portions with widths smaller than corresponding characteristic widths of locking shoulders of locking projections of the base. The base and mounting bracket are configured such that the locking projections of the base may be inserted into the open portions of the locking slots and the base slid into the locking position with the bracket wherein the shoulders of the locking projections of the base are secured from vertical translation away from the locking position by the elongated narrow portions of the locking slots of the raised central locking surface of the mounting bracket. The base is concurrently prevented from horizontal translation away from the locking position by the locking width of the tongue until the tongue is flexed downwardly to its release position.
Typically the base further includes a post for mounting a napkin dispenser, such as a gravity feed napkin dispenser of the general class disclosed in U.S. patent application Ser. No. 10/213,575, filed Aug. 7, 2002, entitled “Gravity-Feed Dispenser and Method of Dispensing Inter-Folded Napkins”the disclosure of which is hereby incorporated by reference. So also, in a preferred embodiment the mounting bracket is stamped from sheet metal and the base is cast from white metal.
Generally, the tongue requires a force of from about 2 to about 10 pounds to move it from the locking position to the release position. In the locking position, the tongue may be generally co-planar with the raised locking surface of the mounting bracket or it may be elevated slightly in portions if so desired. Typically, the tongue requires a force of from about 4 to about 6 pounds to move it from the locking position to the release position.
In a preferred embodiment the assembly of the bracket and base includes biasing means to urge the base and bracket into engagement with each other in the locking position. The biasing means may be, for example, upwardly raised portions defined on the mounting bracket and downwardly projecting ridges on the base located within the hollow cavity. There are optionally provided guide ridges on the base as described hereinafter. The upper portion of the stepped locking recess of the base typically has an L-shaped profile as does a lower portion of the stepped locking recess of the base. The stepped outer profile of the tongue is also generally L-shaped on both sides and may include an arcuate central portion at the end of the tongue.
A particularly preferred arrangement is a countertop mounting base and bracket for releasably securing a napkin dispenser including a base with a generally planar upper surface and a sidewall extending downwardly therefrom to define a hollow cavity wherein there is provided a plurality of downwardly extending vertical ribs including at least two longitudinally extending mounting ribs each of which is provided with at least one engagement ridge thereon. The sidewall also defines a stepped locking recess having an upper portion with a first recessed width and a lower portion with a second recessed width where the upper recessed width is smaller than the lower recessed width. A base is further provided with a plurality of locking projections in the hollow cavity having locking shoulders each of which has a characteristic locking shoulder width.
The mounting bracket is provided with means for securing it to the countertop as well as at least two longitudinal guide tracks each of which has at least one raised engagement portion for interacting with the engagement ridges of the mounting ribs of the base. The bracket further includes a raised central locking surface between the longitudinal guide tracks provided with a moveable tongue adapted to flex with respect to the locking surface from a locking position to a release position, the tongue being provided with a stepped outer profile defining an outer width which is less than equal to the upper recess width of the base and a locking width which is greater than the upper recessed width of the base. The locking surface of the mounting bracket is still further provided with a plurality of locking slots with open portions having widths at least as great as the corresponding characteristic widths of the locking shoulders of the locking projections of the base and elongated narrow portions having widths smaller than corresponding characteristic widths of locking shoulders of locking projections of the base. The base and mounting bracket are configured such that the locking projections on the base may be inserted into the open portions of the locking slots and the base slid into the locking position with the bracket wherein the shoulders of the locking projections of the base are secured from translation away from the locking position by the elongated narrow portions of the locking slots of the raised central locking surface of the mounting bracket. The base is prevented from horizontal translation away from the locking position by the locking width of the tongue until the tongue is flexed downwardly to its release position. In this preferred embodiment the engagement ridges of the base and the raised engagement portions of the mounting bracket urge the mounting bracket and the base into engagement with each other. The engagement portions of the mounting bracket are preferably arcuate portions of the guide tracks of the mounting bracket.
BRIEF DESCRIPTION OF DRAWINGS
The invention is described in detail below with reference to the various Figures in which like numerals designate similar parts and wherein:
FIG. 1 is a perspective view of a gravity feed napkin dispenser mounted on a countertop with the mounting base and bracket in accordance with the present invention;
FIG. 2 is an exploded view in perspective showing the inventive base and mounting bracket of FIG. 1;
FIG. 3 is another exploded view in perspective showing the inventive mounting base and bracket of FIG. 1; and
FIGS. 4-6 are schematic views in perspective of another embodiment of the mounting base and bracket of the present invention.
DETAILED DESCRIPTION
The invention is described in detail below in connection with several embodiments. Such description is for purposes of illustration and exemplification only. Variants to the embodiments illustrated within the spirit and scope of the present invention, set forth in the appended claims, will be readily apparent to those of skill in the art.
Referring to FIGS. 1-3 there is shown a gravity feed napkin dispenser 10 mounted on a post 12 secured to a mounting base 14 configured in accordance with the present invention. Mounting base 14 , in turn, is secured to a mounting bracket 16 as appears in FIGS. 1, 2 and 3 . Napkin dispenser 10 may be of the class described in co-pending application Ser. No. 10/213,575, filed Aug. 7, 2002 entitled “Gravity-Feed Dispenser and Method of Dispensing Inter-Folded Napkins” . The post upon which napkin dispenser 10 is mounted maybe secured to base 14 by way of screws 18 and 20 provided with washers 22 and 24 .
Base 14 is provided with a plurality of ridges such as transverse ribs 26 and 28 , guide ridges 27 , 29 as well as longitudinal ribs 30 and 32 . Ribs 30 and 32 are provided with ridges 34 , 36 , 38 and 40 as can be seen in FIG. 3 . There is also provided on the base a plurality of locking projections in the form of fasteners 42 , 44 , and 46 each of which has a shaft 48 , a shaft 50 and a shaft 52 as well as a head 54 , a head 56 and a head 58 . Fasteners may be screws or bolts or the like which are fitted to be secured in holes 60 , 62 and 64 respectively defined on base 14 . The fastener operates as locking projections as will become apparent from the discussion which follows.
The base is further provided with a stepped recess 66 which has L-shaped profiles at his lower portion 68 and its upper portion 70 as is best seen in FIG. 3 . Note that the width of the upper portion of recess 66 indicated at 72 is less than the width of the lower portion of recess 66 indicated at 74 .
The base is specifically designed to cooperate with the countertop mounting bracket 16 . Mounting bracket 16 has a left track 76 and a right track 78 each of which has a pair of arcuate projections 80 , 82 , 84 , and 86 which interact with the ridges 34 , 36 , 38 and 40 of the base in order to urge the bracket and mounting base into contact with each other when the base is secured to the bracket. The bracket is further provided with a raised central portion 88 which has a tongue 90 as well as locking slots 92 , 94 and 96 . There are further provided guide slots 95 , 97 on either side of the tongue. The mounting bracket is secured to a countertop 98 by way of screws such as screw 100 or by way of double sided tape indicated at 102 and 104 . Note that tongue 90 also has a stepped profile at its portion 106 notably having L-shaped profile on either of its side at 108 and 110 .
In order to secure the napkin dispenser to countertop 98 the mounting bracket 16 is first secured to the countertop. Base 14 optionally provided with mounting post 14 and napkin dispenser 10 is secured to the mounting bracket by way of fasteners 42 , 46 and 48 . That is to say, the fasteners are first inserted into the open portions 106 , 108 and 110 of slots 92 , 94 , and 96 and then the entire base is slid rearwardly in the direction indicated by arrow 120 in FIGS. 2 and 3 such that the fastener heads will be restrained from vertical translation by the narrow portions 112 , 114 , and 116 of slots 92 , 94 and 96 . When the base is slid rearwardly into the locking position shown in FIG. 1 the stepped profile of tongue 90 prevents the base from sliding forwardly to the release position until tongue 90 is pressed downwardly in the direction indicated by arrow 122 . That is to say tongue 90 by virtue of the fact that its width at 124 is wider than the width 72 of the upper portion of the locking recess of base 14 prevents horizontal translation of the base away from the locking position shown in FIG. 1 until tongue 90 is pressed downwardly in the direction indicated by arrow 122 to a release position where the width 124 is below the upper portion of slot 66 as should be fully appreciated from FIGS. 1, 2 and 3 . So also, the various raised portions of tracks 76 and 78 , that is raised portions 80 , 82 , 84 and 86 interact with the engagement ridges 34 , 36 , 38 and 40 of the base to urge the bracket and base into secure contact with one another so that the napkin dispenser will not rock when secures to countertop 98 . Preferably, width 124 of tongue 90 is larger than width 72 of the upper portion of recess 66 but smaller than width 74 of the lower portion of stepped recess 66 . In preferred embodiments, the base and bracket are urged into engagement before tongue 90 latches into place in its locking position in slot 66 . So also, base 14 preferably includes guide ridges 27 , 29 which cooperate with slots 95 , 97 of the mounting bracket in order to orient the base with respect to the bracket and prevent unwanted snagging of the locking projections on slots or holes while the assembly is being locked into engagement. That is to say, ridges 27 , 29 are configured to cooperate with slots 95 , 97 in order to orient the base with respect to the mounting bracket as the base is being engaged with the mounting bracket.
There is shown in FIGS. 4-6 an alternate embodiment of the inventive bracket and mounting base for a napkin dispenser. The mounting base and bracket have generally the features described above in connection with the embodiment of FIGS. 1-3. However, here mounting bracket 16 is secured to countertop 98 by way of four screws such as screws 100 , located on the various corners of the mounting bracket. The mounting bracket has a raised central portion 88 which is generally planar as is tongue 90 . That is to say, tongue 90 is co-planar with the rest of raised portion 88 . Raised portion 88 is only provided with two slots 92 and 94 having open portions 106 and 108 as well as narrow portions 112 and 114 . The base is provided with a stepped locking recess 66 having an upper portion and a lower portion with two L-shaped shoulders on either side of upper and lower parts of the stepped recess 66 . That is, both the upper portion 70 and lower portion 68 of recess 66 have L-shaped profiles on both sides as shown. Here again the base 14 has an upper surface and a hollow cavity 45 for mounting over bracket 16 . There is optionally provided transverse support ribs such as rib 47 to strengthen the base. Here again tongue 90 has a pair of shoulders 128 and 130 to interact with stepped recess 66 in order to secure the base in the locked position until tongue 90 is pressed downwardly to release the base so that it may be slid away from mounting bracket 16 .
While the invention has been described in connection with several embodiments, modifications of those embodiments within the spirit and scope of the present invention will be readily apparent to those of skill in the art. The invention is defined in the appended claims.
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A countertop mounting base and bracket for a napkin dispenser includes a base with a generally planar upper surface provided with a sidewall having a stepped locking recess adapted to cooperate with a stepped tongue of a mounting bracket which is secured directly to the counter. The base and bracket allow for the quick release of a gravity feed napkin dispenser, for example, mounted on the countertop.
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[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 60/827,535, filed Sep. 29, 2006, titled Personalized Photo Costuming Toy, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates in general to a children's activity toy and methods by which individual adherent ornamental objects or descriptive devices can be used to decorate photos of a child and additional people, animals, characters or objects.
BACKGROUND OF THE INVENTION
[0003] Colorforms, die-cut vinyl sheet images and shapes that can be applied to a slick background, have been a popular children's activity toy for many years. They are popular with toddlers and small children because of the interactive creativity used, the physical interest of the material, the variation of the shapes, and the artistic and versatile nature of the pictures and stories that can be created by the child.
[0004] Another favorite activity of children is the study of faces and pictures, particularly their own and people they know or recognize. Toddlers and small children love to look at photos and name the people in the picture. The same activity is relevant when cartoon characters or familiar puppets can be identified and named.
[0005] Children also enjoy coloring and drawing faces and pictures. They often like to draw pictures of themselves and their family. A child would also think that decorating an atypical pattern on a picture is hilarious and fun. For example, drawing a mustache and glasses on a picture of an uncle or sibling would be great fun indeed without the consequential discipline for ruining a photo.
[0006] The combination of these three activities would be an enjoyable, developmentally positive, creative, and unique game with limitless possibilities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] It is believed the present invention will be better understood from the following description taken in conjunction with the accompanying drawings. The drawings and detailed description that follow are intended to be merely illustrative and are not intended to limit the scope of the invention.
[0008] FIG. 1 illustrates a front view of one version of a personalized photo costuming sheet.
[0009] FIG. 2 illustrates a perspective view of one version of a plurality of personalized photo costuming sheets arranged into an album.
[0010] FIG. 3 illustrates a perspective view of a frame having a personalized photo costuming sheet inserted therein shown with associated descriptive devices in the form of stickers.
[0011] FIG. 4 illustrates perspective view of a digital photo display device shown with an associated descriptive device.
[0012] FIG. 5 illustrates a right side view of the digital photo display device of FIG. 4 shown with an input for receiving digital storage medium.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1 , in one version, the personalized photo costuming sheet 10 comprises a photo or primary image 12 of an individual covered in a laminate or protective covering 14 . In one embodiment, the photo 12 is placed into a laminate sleeve 16 via an aperture 18 , surrounded by a border 19 , in the sheet 10 , where the protective covering 14 is a clear transparent pane in the front of the sheet 10 . Referring to FIG. 2 , a plurality of sheets 10 may be combined into an album 20 for use. The sheet 10 may be rigid or flexible, transparent or partially transparent, embossed with images, and include any suitable shape, including polygonal or round. In versions of the sheet 10 having a border 19 , the border 19 may be any suitable size or configuration where, for example, the border may be used to write descriptive messages, to draw, or to provide a larger surface area than a small picture may provide to prevent accidental damage due to markers, or the like. All or a portion of the sheet, including the protective covering and the border 19 , may be erasable or permanent. For example, the border 19 may be marked indelibly, whereas the protective covering 14 may be erasable.
[0014] Referring to FIGS. 1 and 2 , in use, the sheet 10 allows for a child to insert, for example, a photo of a relative into the sleeve 16 such that the photo is protected by the sleeve. After insertion, the child may use any suitable decorating device, including a magnet, a marker, a writing instrument, a sticker, paint, felt, a suction cup, make-up, hair, glitter, glue, beads, dry-erase markers, vinyl objects configured to releasably adhere to a surface, objects comprising adherent backing, or the like, to manipulate the protective coating 14 over the photo to create a secondary image from the photo or primary image 12 . For example, a picture of a child's grandfather may be made to look like a doctor when the child draws, or otherwise uses a descriptive device, on the protective covering 14 to add a stethoscope and scrubs. In this manner, a child may enjoy using treasured family members, or other familiar images, as the basis for creative and imaginative play. The protection of the sleeve may allow children to express themselves without damaging treasured family photos.
[0015] Referring to FIG. 3 , a frame 22 may be provided into which a sheet 24 containing a primary image or photo 12 is inserted for general viewing. By using such a frame 22 , a child may display a secondary image, such as a parent drawn up as a pirate, in a traditional viewing manner. The child may remove the sheet 24 and alter the photograph without, at any time, damaging the primary image of the photograph. The frame 22 may also include a protective pane 26 . When used with a sheet 24 having a secondary image, the protective pane may also be used as a surface for creating an even more complex image. For example, referring to FIG. 3 , a photo of the tree in the backyard in winter may be used as the primary image. When inserted into a sheet 24 , the child may color fill in the foliage of the tree with a decorative device, such as a crayon, to create a vibrant secondary image. Once this image is inserted into the frame 22 , a second decorative device, such as stickers 28 shaped as fruit, may be added to the protective pane 26 of the frame 22 to create an even more vibrant image. In an alternate embodiment, the frame 22 does not have a protective plastic pane 26 and is used to display only a sheet 24 . In one version, the frame 22 includes a storage compartment 30 , which may be a hinged compartment at the back of the frame, to house multiple primary images including photos of a child, family members, pets, or favorite characters. The primary image 12 can be substituted by any of the photos in the storage compartment 30 and placed under the protective covering. It will be appreciated that the frame 22 may be a box frame without a stand and may have any suitable compartment for storing descriptive devices and/or primary images such as photos.
[0016] Referring to FIG. 4 , in one version a digital frame 40 that may be associated with digital primary images, such as photos from a digital camera, is provided such that a person could plug in their digital card, or other electronic medium (not shown), into an input 42 (Shown in FIG. 5 ) in the frame 40 and, for example, load a photo directly into the frame 40 . In this manner, in one version, the frame 40 would display the digital photo in a display 44 having a protective covering or pane 46 over the display 44 such that the primary image, or digital photo, could be modified into a secondary image with a decorative device 50 , such as a crayon, as described herein. The frame 40 may include a cover 48 which may be used to protect the display 44 and/or may be used as a compartment to store decorative devices, or the like. In a further embodiment, the frame itself could include and act as a digital camera. In this case, a person may use the frame as a camera, taking the photo, editing the photo, and then displaying the photo to decorate with various decorative devices.
[0017] The entire invention, including descriptive devices such as vinyl stick-on objects, dry erase-type markers, and photo album or frame could be packaged in a carrying case (not shown). The case would be easy to carry and would help the owner to keep everything together in one place while using the toy in various locations.
[0018] In one version, the activity toy is used in an interactive process, where personal photos are taken at a staffed location, such as at a photographer's studio, and are digitally stored or printed. The staffed location then presents these photos, or any other suitable primary image, to the customer with a number of associated decorative devices. For example, if a parent takes their child to get photographed as a clown, the child could be provided with their own picture and an apparatus as described herein containing decorative elements related to the circus, such as lions, tigers, and bears. Photographs may be taken with the express intent of later modifying them with a specific set of related decorative devices. Such an interactive process may be particularly applicable to theme parks and other vacation areas where additional decorative devices provided with photographs may be used as advertising.
[0019] Staffed locations could be at home shows, mall kiosks, photography studios, theme parks, resorts, or other locations. The service and product could also be provided via the internet from a interactive website. The customer could e-mail or download digital pictures, or other suitable primary images, according to posted guidelines.
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Provided is an activity toy configured to allow for a primary image, such as a photograph, to be converted into a fun and amusing secondary image in a manner that does not harm the original primary image. The toy may be used by children to decorate photographs with decorative devices, such as markers or stickers, without permanently marking the underlying photograph. Provided systems for use with both traditional and digital images.
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention is directed toward sealing means for a closure.
The invention is more particularly directed toward adjustably mounted sealing means for the bottom of a rolling closure, and particularly for the reinforced bottom of a rolling closure.
2. DESCRIPTION OF THE PRIOR ART
Rolling closures are built in size to nearly, but not completely, close openings. In the closed position of the rolling closure, a slight gap exists between the bottom of the closure and the bottom of the opening. This gap is normally closed by sealing means fastened on the bottom of the closure. One simple form of sealing means which can be employed on the bottom of the closure uses a flexible strip of material. A pair of suitable mounting means are provided on the bottom of the closure, one on the bottom front edge of the closure and one on the bottom, back edge of the closure. Mounting means on the sides of the strip cooperate with the mounting means on the bottom of the closure to hang the strip from the bottom of the closure in a downwardly depending loop to form a seal.
If the closure is made in any one of several different thicknesses, the distance between the mounting means on the closure bottom can vary requiring different widths of sealing strips to close the same size of bottom gap. Alternatively, the different width closures can be made with different bottoms, each closure bottom providing the same distance between the mounting means so that only one size of sealing strip is needed. In either case however different sizes of sealing strips or of closure bottoms, are needed to provide the same bottom seal for closures of different thickness and this is expensive.
SUMMARY OF THE INVENTION
It is therefore the purpose of the present invention to provide sealing means on the bottom of a rolling closure which can be adjustably mounted to accomodate closures of different thickness in a relatively simple and inexpensive manner.
The bottom of rolling closures can be easily damaged and it is known to reinforce the bottom edge to minimize damage. In accordance with the preferred embodiment of the present invention, a reinforcement member employed to strengthen the bottom of a rolling closure is also employed in adjustably mounting the sealing means to the closure in a manner to accomodate closures of different thickness. The single reinforcement member thus is employed for two functions simultaneously thereby further reducing expense.
In accordance with the present invention, the sealing means employs a sealing strip of one width for all thicknesses of closure. First mounting means are provided in one location on the bottom of the closure to receive one side of the sealing strip. Two or more other spaced-apart mounting means are provided on the bottom of the closure, spaced from the first mounting means. The other side of the sealing strip is mounted in one of these other mounting means. Which one of the other mounting means is employed is dependent on the thickness of the closure in order to always provide the same size of loop as formed by the strip. The first mounting means is provided in the same location on the bottom side of the bottom closure panel irregardless of the width of the panel. The two or more other mounting means are preferably provided on the bottom side of the reinforcing member which is attached to the side of the bottom closure panel. Thus the distance of the other mounting means from the one mounting means varies according to the thickness of the bottom panel. However one of the other mounting means is always in the proper position to receive the other side of the sealing strip to form a loop of the proper size irregardless of which of several panel widths is used.
The invention is particularly directed toward a closure having a bottom surface and a flexible sealing strip having first mounting means on one side of the strip and second mounting means, parallel to the first mounting means, on the other side of the strip. A first mounting means is provided on the bottom surface of the closure and at least two other spaced-apart mounting means are provided on the bottom surface of the closure, spaced from the first mounting means. The first mounting means on the strip is mounted in the first mounting means on the closure and the second mounting means on the strip is mounted in one of the other mounting means on the closure dependent on the thickness of the closure.
The closure has a bottom panel with its bottom side forming part of the bottom surface of the closure. The closure also has a reinforcing member mounted to the bottom panel with the bottom side of the reinforcing member forming the other part of the bottom surface of the closure. The first mounting means in the closure is in the bottom side of the bottom panel. The other mounting means in the closure are in the bottom side of the reinforcing member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail having reference to the accompanying drawings in which:
FIG. 1 is a cross-section view of the bottom of a closure;
FIG. 2 is a cross-section view of a sealing strip;
FIG. 3a is a cross-section view of the closure bottom with a thin panel; and
FIG. 3b is a cross-section view of the closure bottom with a thick panel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The rolling closure 1, as shown in FIG. 1, comprises a series of panels or slats 3 pivotally joined together by suitable hinge means 5 at their adjacent long sides. The bottom surface 7 of the rolling closure is positioned close to the bottom 9 of an opening 11 when the closure 1 closes opening 11. There is a gap 13 however between the bottom surface 7 of the closure 1, and the bottom 9 of the opening 11.
The bottom side 15 of the lowermost panel 3a in the closure 1 forms part of the bottom surface 7 of the closure. A reinforcing member 17, part of the closure 1, is mounted to the inside 19 of the bottom panel 3a by suitable fastening means 21. The bottom side 23 of the reinforcing member 17 forms the remaining part of the bottom surface 7 of the closure 1. The two bottom sides 15, 23 of the panel 3a, and member 17 respectively, preferably are aligned and parallel to the bottom 9 of opening 11.
The reinforcing member 17 preferably comprises an angle member having one leg 25 fastened to the inside 19 of the bottom panel 3a. The other leg 27 extends transversely away from the inside 19 of the bottom panel 3a with its outer side forming the bottom side 23 of the reinforcing member 17. The reinforcing member 17 stiffens the bottom edge of the closure 1, making it stronger. The reinforcing member 17 also provides an enlarged area for use in mounting a sealing member 31 to the bottom edge of the closure as will be described.
The sealing member 31, as shown in FIG. 2, comprises a long, narrow strip 33 of flexible, preferably resilient, material having a first long side 35 and a parallel second long side 37. First mounting means in the form of a rib 39 are provided on the first side 35 of the strip 33, and second mounting means, also in the form of a rib 41, are provided on the second side 37 of the strip. The ribs 39, 41 have the same cross-sectional shape, preferably circular, and have a diameter larger than the thickness of strip 33.
Means are provided in the bottom surface 7 of the rolling closure 1 for detachably adjustably mounting the sealing strip 33 thereto to form sealing means for the closure. The mounting means includes a first mounting groove 43 located in the bottom side 15 of the bottom panel 3a. This first mounting groove 43 preferably is formed in the bottom of the front wall 45 of the panel. Two or more other, spaced-apart mounting grooves are located in the bottom side 23 of the reinforcing member 17 in its other leg 27. Three other mounting grooves 47, 49, 51 are shown in leg 27 in FIG. 1. The first and the other mounting grooves 43, 47, 49, 51 are all identical with each groove having a base 53 with a cross-sectional shape substantially the same as the cross-sectional shape of the ribs 39, 41 on the sealing member 31. Each groove also has a slot, substantially equal in width to the thickness of the strip 33 of the sealing member 31, providing entry to the base 53. The grooves 43, 47, 49, 51 extend across the width of the closure 1 and are parallel to each other, and to the front wall 45 of the panel 3a.
The sealing member 31 is mounted on the closure 1 by sliding its first mounting means, rib 39, into the first mounting groove 43 in the bottom panel 3a of the closure. The second mounting means, rib 41, on sealing member 31, is simultaneously slid into one of the grooves 47, 49, 51 in the reinforcing member 17. The strip 33 is suspended from the bottom surface 7 of the closure 1 by its ribs 39, 41 forming a loop 57, the bottom 59 of which rests on the bottom 9 of the opening 11, as shown in FIG. 3a. The loop 57 closes the gap 13 between the bottom 7 of the closure 1 and the bottom 9 of the opening 11.
The other grooves 47, 49, 51 in the reinforcing member 17 permit adjustment in the mounting of the sealing member 31 on the closure 1. When the closure employs narrow panels 3, one inch thick for example, the second mounting means, rib 41, on sealing member 31 is mounted in the other mounting groove 51 farthest removed from the first mounting groove 43, as shown in FIG. 3a. When the closure employs thick panels 3, two inches thick for example, the second mounting rib 41 is mounted in the other mounting groove 47 closest to the first mounting groove 43 as shown in FIG. 3b. This arrangement permits the sealing member 31 to properly close gap 13 irregardless of whether a thick or thin panel 3 is used in the closure. If a medium thick panel 3 is used, groove 49 is used to mount the sealing member 31.
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Sealing means for the bottom of a rolling closure which sealing means can be adjustably mounted on the closure. The adjustable mounting provides a seal of substantially uniform size irregardless of which one of several panel thicknesses make up the closure.
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TECHNICAL FIELD
[0001] The present invention relates to fungal metabolism/transformation of lipid substrates to produce fats and more particularly oils and their extracts containing biologically-active chemical compounds for the treatment or prophylaxis of diseases, disorders or conditions in humans and other animals.
BACKGROUND OF THE INVENTION
[0002] With the growth of the alternative/complementary medicine industry and the general perception in some areas that the products are “snake oil” remedies, there is a pressing need to ensure that products supplied by this alternative industry have reproducible efficacy and are safe for use by the general public. However, due to recent adverse publicity by the press and government regulators there is an absolute requirement for alternative medicines to meet strict guidelines regarding the quality of the raw materials and the method of manufacture. One of the major difficulties with alternative medicines is that the ingredients used are often composed of materials which in most cases may contain many different chemical compounds. Hence there is an enormous challenge involved to ensure efficacy and safety of the products for use by society. One of the major reasons for the lack of knowledge of the effectiveness of these products is that the alternative and complementary medical industry generally pride themselves on the fact these products are not animal tested, hence their claims cannot be validated.
[0003] Historically, the animal and plant oil industries are among the oldest in the world, hence procedures used in this industry are well established. In addition the industrial and medical applications, of which there are many, are well documented in the literature. However, many oils such as olive, evening primrose oil, flaxseed oil, cod liver oil and emu oil are used to treat a variety of medical conditions and diseases but virtually no attention has been paid to the difficulty in reproducing efficacy and safety data for these type of products. In fact, over the past thirteen years of animal and chemical testing of a large variety of many different types and batches of animal and plant oils, large variation in biological activity and chemical composition has been observed.
[0004] It has been increasingly recognised in this area that in order to increase the credibility of complementary/alternative medicines based on animal and plant extracts, particularly oils, quality control in terms of reproducibility of efficacy and safety data for these type of products is of foremost concern.
Object of the Invention
[0005] It is therefore an object of the present invention to provide processes for the production of animal and plant-derived oils and their extracts containing biologically-active chemical compounds having therapeutic and prophylactic activity in respect of a wide range of diseases and conditions in humans and other animals.
[0006] It is another object of the present invention to provide pharmaceutical compositions formulated for administration by any route, including without limitation, oral, buccal, sublingual, rectal, parenteral, topical, inhalational, injectable and transdermal, preferably oral or topical, including biologically-active oils and/or their extracts which demonstrate efficacy across a broad spectrum of diseases, disorders or conditions in humans and other animals, together with pharmaceutically acceptable excipients, carriers or adjuvants.
[0007] It is also an object of the present invention to provide a method for the treatment or prophylaxis of a wide range of diseases, disorders and conditions in humans and other animals by the administration of biologically-active oils and/or their extracts obtained according to the processes of the present invention.
[0008] It is also an object of the present invention to provide a method for the treatment or prophylaxis of a wide range of diseases, disorders and conditions in humans and other animals by the administration of the fatty acid esters and amides of biologically-active oils and/or their extracts.
[0009] It is a further object of the present invention to provide the use of biologically-active oils and/or their extracts in the manufacture of pharmaceutical formulations for the treatment or prophylaxis of a wide range of diseases and conditions in humans and other animals.
SUMMARY OF THE INVENTION
[0010] This invention is based on the identification of the major factor/s responsible for the variation in quality of plant and animal derived oils, namely the transformation of the lipid substrates by fungi growing in and on the lipid substrate. The quality of the fat or oil produced depends on the type and number of fungi (enzymes), lipid substrate, temperature, humidity and length (time) of incubation prior to rendering. The basis of this invention therefore relates to the controlled use of fungi to transform lipid substrate/s to produce oils which contain biologically-active chemical compounds. It has been established by the present inventor that exposure of the lipid substrate to fungi is responsible for the major variation in biological activity (efficacy) rather than temperature, oxygen and light during processing and storage, although these latter factors may have some minor influence.
[0011] Accordingly, a first aspect of the present invention provides a process for the production of fats or oils and their extracts containing biologically-active chemical compounds from a lipid substrate, the process comprising:
a) inoculation of a lipid substrate with a fungal mixture, b) incubating the inoculated substrate for a period of between about 7-120 days at a temperature of between about 4-35° C., at a humidity of between about 75-100%, and c) processing, said incubated substrate mixture to obtain a biologically active fat or oil.
[0015] A related aspect of the present invention provides a process for the production of oils and their extracts containing biologically-active chemical compounds from a lipid substrate, the process comprising
a) inoculation of a lipid substrate with fungally derived lipolytic enzymes b) incubating the inoculated substrate for a period of between about 7-120 days at a temperature of between about 4-35° C., at a humidity of between about 75-100%, and c) processing said substrate mixture to obtain a biologically active fat or oil.
[0019] In step b) typically the period of incubation is between about 7 to 28 days at high humidity of between about 80-100%.
[0020] In step c), if the lipid is animal derived, it is typical that the product is a biologically active oil obtained by rendering said inoculated substrate. Alternatively, if said lipid is plant or seed derived, the biologically active oil is obtained by cold pressing or solvent extraction of said inoculated substrate mixture.
[0021] There is also provided a biologically active product, particularly an oil when produced by the process of the first aspect of the present invention described above.
[0022] The typical steps/procedures which must be performed in order to produce the biologically-active oils and fats; assuming we have pure fungi in storage are:
1. Inoculating the sterilised lipid substrate (e.g. animal lipid) with the appropriate fungal mixture; 2. Incubating the above mixture for a specified period of time and humidity; 3. Rendering the above mixture; 4. Centrifuging the rendered mixture produced in step 3 ; 5. Filtering the oil produced from the centrifuge step; 6. Sterilising the oil at 135° C. for two hours; 7. Filtering the oil after sterilising; 8. Storage of the oil; 9. Extraction of the oil if required.
[0032] Providing the above procedures are repeated the oil produced will be reproducible within experimental error, as this is a biological process in which some variation will be certain to occur.
[0033] Bacteria are not involved in the transformation process. While not wishing to be bound by any theory, it appears that the fungi penetrate the lipid cell and excrete enzymes that digest the lipid within the cell. Breakdown products are released and some are absorbed by the fungus and transformed internally while others appear in the supernatant.
[0034] The fungal mixture used to inoculate the lipid substrate and which is the source of the fungally-derived lipolytic enzymes may be intact/whole fungal organisms, pure fungi, single fungi or mixed fungi, active enzyme extracts thereof, genetically modified organisms or modified enzymes. The process of the present invention transforms the lipids, resulting in fats or oils containing biologically-active chemical compounds which are suitable for treating a wide range of human and veterinary diseases. It is noted that using this method of producing oils and their extracts the amount of free fatty acids, mono and diglycerides are enriched, for example the level of total free fatty acids some plant animal and plant oils is up to or exceeding 14%. The compounds found in the oils and their extracts act synergistically to give the desired biochemical action in humans and animals for the treatment of a wide range of diseases and conditions.
[0035] Typically, the lipid substrate can be selected from animal or plant sources, of either terrestrial or marine origin, or the substrate can be constituted from lipids or their extracts impregnated onto artificial substrates supplemented with mineral and organic amendments (see Waller et al 2002, Plant Pathologists Pocketbook 3rd Edition, CABI, New York). Sources of animal lipids include goanna, sheep, chicken, emu, ostrich, camel, duck, geese, pig, cattle, horse, mutton bird, fish and shellfish including mussels. Sources of plant oils include seeds/nuts of Macadamia sp, Canarium spp, peanut, sunflower, safflower, linseed, soybean, wheat, oats, barley, almond, avocado, cashew, quandong, maize, wattle, olive, palm and rice. Other vegetable/plant/seed sources include coconut, pili nut, ngali nut, neem seed, sesame and canola.
[0036] Typically, the fungi inoculated onto the lipid substrate will have been isolated from the substrate (ie is endogenous to the lipid substrate) and found to transform the specific or similar substrates. Such fungi are typically found in the sexual and asexual states of the Phyla Zygomycotina, Ascomycotina and Basidiomycotina. This is therefore understood to cover the fungi Deuteromycetes which is the asexual state of the main phyla. Fungi also typically found to transform lipid substrates include Phoma sp, Cladosporium sp, Rhodotorula mucilaginosa, Cryptococcus albidus, Trichosporon pullulans, Mucor spp, Epicoccom purpurescens, Rhizopus stolonifer, Penicillium chrysogenum, Nigrospora sphaerica, Chaetomium globosum . Fungi demonstrating the ability to transform or having this potential may be typically improved by either traditional or molecular genetic techniques to enhance enzyme formation and activity.
[0037] The substrate may also or instead be inoculated with enzymes derived from fungi. Typically the additional enzymes are endogenous to the fungi, but can also be developed from alternative sources or genetically modified isolates. Such enzymes may also be purified and their activity increased by alteration of their structure using physical, chemical or other techniques.
[0038] Typically, the lipid substrate is sterilised and then inoculated with one or more fungi or their enzymes as required. The substrate may be sliced, minced, chopped or ground to enable it to be spread in a layer typically between 0.5 and 10 cm on a surface that may be a solid sheet, or perforated to allow oxygen to the lower surface and oil to drip from the substrate and be collected in a suitable container. Inoculation uses standard procedures (see Waller et al 2002) including spraying or painting the lipid surface with fungal spores suspended in sterile water. The substrate is then typically incubated for a period between about 7 days and about 120 days, more typically between about 7 and 65 days, or about 7 and 56 days, or about 7 and 42 days, or about 7 and 35 days. Even more typically, the substrate is incubated for a period between about 7 and 28 days or about 7 and 21 days and most typically between 14, 21, 28, 35, 42, 56, and 65 days. The inoculated lipid substrate is incubated at a temperature between 4-35° C., typically around 15-20° C., and a relative humidity between 80-100%, typically 95%.
[0039] Following incubation the animal lipid substrate containing the fungi is minced or ground and transferred to a stainless vessel prior to the rendering process. This process typically involves rendering at a temperature between 40-80° C., typically around 70-75° C. with constant slow speed stirring until the lipid substrate has melted into oil. This oil is then typically centrifuged and filtered and can be further extracted. The filtrate which contains the biologically active oil is then typically further sterilised by heating for a period of between about 15 minutes and about 8 hours, more typically between about 1 hour and 6 hours, even more typically between about 1 hour and 4 hours. Typically the filtrate is heated to a temperature between about 100-160° C., more typically between about 110-150° C. and even more typically between about 120-140° C., most typically about 130-135° C.
[0040] In the case of plant seed, nut oils or other lipid sources not of animal origin, the inoculated and incubated lipid substrate/s containing fungi may be minced or ground prior to cold pressing using a screw press, the oil from the screw press then being centrifuged and filtered. This oil is then typically sterilised by heating for a period of between about 15 minutes and about 8 hours, more typically between about 1 hour and 6 hours, even more typically between about 1 hour and 4 hours. Typically the oil is heated to a temperature between about 100-160° C., more typically between about 110-150° C. and even more typically between about 120-140° C., most typically about 130-135° C. The oil produced is then treated as for animal substrates.
[0041] The oil obtained from the above processes may then be subjected to solvent extraction which typically involves mixing the oil on a mass or volume basis in the ratio of 1/1 or 2/1 solvent to oil then cooling over a temperature range of 20° C. to −40° C. for a time period from 30 minutes up to 24 hours. The solvent is decanted or poured off, centrifuged if required containing, and evaporated dryness to obtain the extract. The resulting residue contains the biologically-active chemical compounds.
[0042] The oil or extracts from the above processes may also be subjected (including any derivatives obtained by chemical treatment of oils and their extracts) to the following processes in order to obtain specific fractions or chemical compounds,
(1) High performance liquid chromatography, experimental conditions used will depend on the chemical and physical properties of chemical compounds required for treatment of specific human and animal diseases and conditions. (2) Super fluid chromatography, experimental conditions used will depend on the chemical and physical properties of chemical compounds required for treatment of specific human and animal diseases and conditions. (3) Wiped-Film Molecular Still or Evaporator (eg Pope), experimental conditions used will depend on the chemical and physical properties of chemical compounds required for treatment of specific human and animal diseases and conditions. (4) Hybrid Still incorporating Wiped-Film Evaporator and Fractional Distillation Column. (5) Molecular Distillation Plant or any combination of the above items in (3), (4) and (5), experimental conditions used will depend on the chemical and physical properties of chemical compounds required for treatment of specific human and animal diseases and conditions.
[0048] A second aspect of the present invention provides a method for the treatment or prophylaxis of a wide range of diseases, disorders and conditions in humans and other animals by the administration of the fatty acid esters and/or amides of biologically-active oils and/or their extracts. Esters include methyl, ethyl, propyl and isopropyl groups. Methyl and isopropyl esters of the extracts of these oils have been in-vivo tested successfully on rats for the treatment of arthritis with success.
[0049] A related aspect of the present invention provides the use of the fatty acid esters and/or amides of biologically-active oils produced according to the present invention, and/or their extracts, for the preparation of a medicament for the treatment or prophylaxis of a wide range of diseases, disorders and conditions in humans and other animals by the administration.
[0050] Typically, the biologically active oils produced can be used to treat and/or prevent a wide range of diseases, disorders or conditions in humans and other animals. Typical diseases, disorders or conditions which may be treated or prevented include: respiratory diseases or conditions such as asthma, bronchial disease and chronic obstructive pulmonary disease (COPD), vascular diseases or conditions such as atherosclerosis, coronary artery diseases, hypertension and sickle cell disease-associated vaso-occlusion, skin diseases or conditions such as various dermatitis, psoriasis and atopic eczema, all types of burns, gastrointestinal diseases or conditions such as ulcers, gastric reflux, inflammatory bowel disease, ulcerative colitis, Crohn's disease, pancreatitis and periodontal disease, cancers including bowel cancer and prostate cancer, sarcoidosis, septic shock, musculo-skeletal diseases or conditions such as arthritis including osteoarthritis and rheumatoid arthritis, chronic joint and ligament pain, leukemia, diabetes, allergy including otitis media and ocular allergy, uveitis, dysmenorrhoea, kidney diseases or conditions including glomerulonephritis and nephritic syndrome and prostate diseases or conditions such as benign prostate hyperplasia, and a wide variety of inflammatory disorders. The biologically active oils produced can also increase bone mass density and improve bone strength and connective tissue disorders.
[0051] The biologically active oils and their extracts appear to inhibit the synthesis of the C reactive protein ie they are C reactive protein inhibitors. (Refer to test results for patient 7 in the examples of therapeutic activity below). Hence these oils and their extracts may used to treat a wide range of human and animal diseases and conditions associated with the production of the C reactive protein.
[0052] C-Reactive Protein (CRP) belongs to the pentraxin family of proteins, so-called because it has five identical subunits, encoded by a single gene on chromosome 1, which associate to form a stable disc-like pentameric structure. It was so named because it reacts with the somatic C polysaccharide of Streptococcus pneumoniae , and was first discovered in 1930 by Tillet and Frances. In the presence of calcium, CRP specifically binds to phosphocholine moieties. This gives CRP a host-defensive role, as phosphocholine is found in microbial polysaccharides (where CRP-binding activates the classical complement pathway and opsonises ligands for phagocytosis), the pro-inflammatory platelet-activating factor (PAF) (which is neutralised), and polymorphs (which are down-regulated).
[0053] CRP is exclusively made in the liver and is secreted in increased amounts within 6 hours of an acute inflammatory stimulus. The plasma level can double at least every 8 hours, reaching a peak after about 50 hours. After effective treatment or removal of the inflammatory stimulus, levels can fall almost as rapidly as the 5-7-hour plasma half-life of labelled exogenous CRP. The only condition that interferes with the “normal” CRP response is severe hepatocellular impairment.
[0054] Some of the most common conditions associated with major elevations of CRP levels are:
(a) Inflammatory diseases such as various forms of arthritis including rheumatoid arthritis, psoriatic arthritis andjuvenile chronic arthritis, Crohn's disease, ulcerative colitis, Reiter's disease etc. (b) Malignancy such as lymphoma, sarcoma. (c) Necrosis such as myocardial infarction, tumour embolisation and acute pancreatitis. (d) Trauma such as burns and fractures. (e) Rheumatic fever, tuberculosis, allograft rejection and leukemia.
[0060] The biologically active oils and their extracts appear to inhibit the secretion of prostaglandin PGE 2 from the mouse fibroblast cell line. Hence this result (see Table 9 which summarises the Percent Inhibition of Secreted PGE 2 from 3T3 cells exposed to Oil Extracts) confirms that these oils and extracts appear to inhibit Cyclooxygenase pathways although this assay is a general assay which gives results for both COX-1 and COX-2 but from adhoc human data and animal studies these oils and extracts inhibit bleeding hence COX-1 pathway may not be involved. Hence these oils and extracts can be used to treat a wide range of human and animal diseases and condition associated with the COX pathway. These types of inhibitors may be used to treat diseases and conditions in humans and animals such as rheumatoid arthritis, osteoarthritis, pain, etc.
[0061] The biologically active extracts appear to inhibit leukotriene synthesis ie they are 5-lipoxygenase inhibitors.
[0062] The biologically active oils produced have also been noted to synergistically enhance the efficacy of a variety of pharmaceuticals including dexamethasone and prednisone. Such synergy is of great clinical benefit as raised levels of pro-inflammatory leukotrienes or 5-lipoxygenase are associated not only with asthma but also with rheumatoid arthritis, osteoarthritis, scleroderma and inflammatory bowel diseases such as Crohn's disease, and the administration of an active oil of the present invention allows lower doses of steroids to be used. (See FIG. 4 for the synergistic action of a lipoxygenase inhibitor plus a steroid.)
[0063] A third aspect of the present invention provides a pharmaceutical composition comprising a biologically active oil, or a fatty acid ester and/or amide of a biologically-active oil and/or an extract thereof, together with a pharmaceutically acceptable carrier, excipient or adjuvant. Typically, the compositions can be in the form of immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting, and combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
[0065] FIG. 1 is a flow chart of the process for extraction of biologically active oils from the crude oil/filtrate.
[0066] FIG. 2 is a flow chart of the process for production of biologically active oils according to the present invention.
[0067] FIG. 3 is a summary of the enzymatic pathways acted upon by the biologically active oils to suppress pro-inflammatory leukotrienes
[0068] FIG. 4 Shows how steroids and the lipoxygenase inhibitor(s)(LI) from a biologically-active emu oil can act co-operatively to suppress pro-inflammatory leukotrienes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0069] As is clear from the foregoing, this invention relates to the fungal metabolism/transformation of lipid substrates. The fungi can be endogenous or exogenous to the lipid substrate. However, only fungi with very specific capabilities will grow on lipid substrates. Not all have the potential to transform the lipid substrate from which they were isolated, or other lipid substrates. Hence the present invention can utilise all fungi which grow on and metabolise/transform lipid substrates to produce oils which contain biologically-active chemical compounds.
[0000] a) Isolation of Fungi
[0070] Fungi are isolated and cultured from lipids using standard methods (see Waller et al 2002 for some common methods). Fungi can be found growing on or near the surface of naturally colonised lipidic substrates. Typically, the fungi are isolated from lipidic substrates naturally colonised by the fungi onto various standard agar media using standard techniques. Typically, fungi growing on the surface of lipid substrates are obtained by removing fragments of fungus with a sterile probe and placing the fragment on media for subsequent growth and identification. Typically endogenous fungi are obtained following surface sterilisation of the lipid substrate with alcohol or hypochlorite. Fragments of the lipid substrate are then placed on media containing antibiotics to suppress bacterial growth. Emerging fungi are sub-cultured to fresh sterile media for growth and subsequent identification. Media typically include Potato Dextrose agar, Malt Extract agar, V8 juice agar, Cornmeal agar, Oatmeal agar. Typically, the fungi can be subcultured from isolation plates on the same or other standard media.
[0071] Such fungi can undergo traditional or genetic techniques to enhance formation and activity of target compounds. Fungi isolated from lipidic substrates can be tested for their transformation of lipid substrates. Those fungi found to transform most effectively can replace less effective isolates to increase production of biologically-active compounds. These processes are used widely to enhance production of biologically active compounds and were used, for instance, to enhance production of penicillin. Enzymes can be isolated and purified from the fungi and their activity maximised using physical or chemical treatment techniques, according to R. K. Saxena, Anita Sheoran, Bhoopander Giri, W. Sheba Davidson, (2003) Review of Purification Strategies for Microbial Lipases, 52, 1-18 which is incorporated herein by reference. Enzymes are only isolated from fungi which are known to grow on and transform/metabolise lipid substrates to produce oil containing biologically-active chemical compounds.
[0000] b) Storage of Fungi and Enzymes
[0072] Fungi are stored using standard techniques such as lyophilisation, storage at low temperatures, in sterile water, on nutrient agar under oil, or when desiccated (see Waller et al 2002 for some standards techniques of storing fungi).
[0000] c) Storage of Lipid Substrates
[0073] Animal and plant lipid substrates are stored in enclosed containers. Animal lipids are stored at temperatures typically below −18° C. Animal lipids may be freeze-dried and ground or minced prior to storage at low temperatures. Plant lipid substrates are stored under standard conditions of low humidity, typically below 9%. Temperature is maintained below 30° C.
[0000] d) Sterilisation of Animal and Plant Lipid Substrates (of Marine and Terrestrial Origin) Prior to Inoculation
[0074] Prior to transformation, the lipid substrate is sterilised in order to remove endogenous microbes. Sterilisation may include washing in ethanol or hypochlorite solution, gamma irradiation or its equivalent, or heat treatment (see Waller et al 2002, Plant Pathologists Pocketbook 3 rd Edition, CABI, New York for examples of techniques in common use). In addition, lipid substrate/s may be modified by addition of specific mineral and organic additives such as found in Czapek Dox agar (see Waller for a recipe for Czapek Dox, a commonly used mineral supplement).
[0075] Similarly, prior to transformation, the plant substrate is sterilised in order to remove endogenous microbes. Sterilisation may include washing in ethanol or hypochlorite solution, gamma irradiation or its equivalent, or heat treatment (see Waller et al 2002, Plant Pathologists Pocketbook 3 rd Edition, CABI, New York for examples of techniques in common use). In addition, lipid substrate/s may be modified by addition of specific mineral and organic additives such as those found in Czapek Dox agar (see Waller for a recipe for Czapek Dox).
[0000] e) Inoculation of Lipid Substrate
[0076] The lipid substrate is inoculated with one or more fungi or their enzymes as required. The substrate may be sliced, minced, chopped or ground to enable it to be spread in a layer typically between 0.5 and 10 cm on a surface that may be a solid sheet, or perforated to allow oxygen to the lower surface and oil to drip from the substrate and be collected in a suitable container. Inoculation uses standard procedures (see Waller et al 2002) including spraying or painting the lipid surface with fungal spores suspended in sterile water. The inoculated lipid substrate is incubated at a temperature between 4-35° C. commonly around 15-20° C., and a relative humidity between 80-100%, typically 95%. The substrate is then typically incubated for a period between 7 days and about 120 days, and typically between 7, 14, 28, 35, 42, 56, 65 days.
[0000] f) Production of Oils and Extraction of Biologically Active Compounds
[0077] The lipid substrate used during fungal metabolism will determine the method used to extract the biologically active oil. The three main methods that may be used are: temperature rendering, solvent extraction and cold pressing. The latter two methods are used only in respect of the production of plant oils.
[0078] Following incubation the animal lipid substrate containing the fungi is minced or ground and transferred to a stainless vessel prior to the rendering process. This process typically involves rendering at a temperature between 40-80° C., usual temperature set around 70-75° C. with constant slow speed stirring until the lipid substrate has melted into oil; heating may be electrical, or by steam or hot water. The liquid in the vessel that contains the oil is then centrifuged, followed by filtration. The residue that remains from the centrifuging step may then be subjected to further extractions, generally using standard procedures used in the plant-seed oil and pharmaceutical industries as well as in natural product isolations used in research. The filtrate, which contains the biologically active oil, is then heated for a further period of between 15 minutes and about 8 hours at temperatures ranging from 100 to about 160° C. under inert gas atmosphere or at normal atmospheric conditions. Typical conditions that are commonly used are 135° C. for 2 hours under inert gas atmosphere such as nitrogen. This step sterilises the oil, and in addition denatures any protein/s present. After cooling to a suitable temperature using a heat exchanger the oil is then filtered again to remove any residual precipitated protein and/or fungi particulate which may be present. The oil is packaged into 20 and or 200 litre pharmaceutical grade drums for storage. For extraction of biologically active compounds from oil refer to FIG. 1 .
[0079] In the case of plant seed, nut oils or other lipid sources not of animal origin the inoculated and incubated lipid substrate/s containing fungi may be minced or ground prior to cold pressing using a screw press, the oil from the screw press then being centrifuged and filtered. This oil is heated for a further period of between 15 minutes and about 8 hours at temperatures ranging from 100 to about 160° C. under inert gas atmosphere or at normal atmospheric conditions. Typical conditions commonly used are 135° C. for 2 hours under inert gas atmosphere such as nitrogen. This step sterilises the oil, and in addition denatures any protein/s that may be present. After cooling to a suitable temperature using a heat exchanger the oil is filtered again to remove any residual precipitated protein and/or fungi particulate. The oil is packaged into 20 and or 200 litre pharmaceutical grade drums for storage. The cake from the press is solvent extracted using a range of common solvents selected from such as hexane, isohexane, petroleum spirits, methanol, isopropanol, propanol, ethanol and diethyl ether. The solvent is then removed by evaporation and recovered for future use. The techniques used are standard in plant oil industry. The oil produced is then treated as described for animal substrates.
[0080] The oil obtained from the above processes may then be subjected to solvent extraction at various temperatures typically using one or more of the following solvents: methanol, ethanol, propanol, isopropanol, diethyl ether, light petroleum spirits, butanol, acetone and acetonitrile. This procedure involve mixing the oil on a mass or volume basis in the ratio of 1/1 or 2/1 solvent to oil then cooling over a temperature range of 20° C. to −40° C. for a time period from 30 minutes up to 24 hours. The solvent is decanted or poured off, centrifuged if required containing the biologically-active molecules and evaporated dryness to obtain the extract. Typical conditions provide 100 gm of oil thoroughly mixed with 100 gm methanol and held at 0C for 16 hours, then centrifuged if required and solvent evaporated on laboratory scale using a rotary film evaporator. The resulting residue contains the biologically-active chemical compounds. Solvent should be recovered for recycling.
[0000] Forms of Administration:
[0081] It is possible in the pharmaceutical composition of the inventive subject matter for is the dosage form to combine various forms of release, which include without limitation, immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting, and combinations thereof. The ability to obtain immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting characteristics and combinations thereof is performed using well known procedures and techniques available to the ordinary artisan. Each of these specific techniques or procedures for obtaining the release characteristics is well known to those persons skilled in the art. As used herein, a “controlled release form” means any form having at least one component formulated for controlled release. As used herein, “immediate release form” means any form having at least some of its pharmaceutically active components formulated for immediate release.
[0082] A variety of administration routes are available and the route selected will depend on the particular condition being treated and the dosage required for therapeutic efficacy. In the methods and compositions of the present invention, any mode of administration is acceptable and include oral, rectal, topical, nasal, transdermal or parenteral (eg subcutaneous, intramuscular and intravenous) routes.
[0083] Any biologically-acceptable dosage form, and combinations thereof, are contemplated by the inventive subject matter. Examples of such dosage forms include, without limitation, chewable tablets, quick dissolve tablets, effervescent tablets, reconstitutable powders, elixirs, liquids, solutions, suspensions, emulsions, tablets, multi-layer tablets, bi-layer tablets, capsules, soft gelatin capsules, lard gelatin capsules, caplets, lozenges, chewable lozenges, beads, powders, granules, particles, microparticles, dispersible granules, cachets, douches, suppositories, creams, lotions, topicals, inhalants, aerosol inhalants, patches, particle inhalants, implants, depot implants, ingestibles, injectables, infusions, functional foods and combinations thereof. The preparation of the above dosage is well known to those persons skilled in the art. Generally, each would contain a predetermined amount of the active component in association with a carrier which constitutes one or more appropriate ingredients.
[0084] Compositions suitable for parenteral administration conveniently comprise a sterile aqueous preparation of the active component which is formulated according to known methods using suitable dispersing and suspending agents. A sterile injectable preparation may be formulated as a solution or suspension in a non-toxic parenterally acceptable diluent or solvent (eg water, isotonic sodium chloride solution). Sterile fixed oils can also be employed as a solvent or suspending medium.
[0085] Typical dosages extracts from 0.01 mg to 1000 mg per kilogram, several doses may be necessary throughout the day, oil from 5 mL to 20 mL per day in 5 mL doses. Initial daily doses of 30 or 40 ml of pure oil is also typical. Multiple doses per day are contemplated to achieve appropriate systemic levels of the active component. The formulation of therapeutic compositions is well known to persons skilled in this field. Suitable pharmaceutically acceptable carriers and/or diluents include any and all conventional solvents, dispersion media, fillers, solid carriers, aqueous solutions, coatings, isotonic and absorption delaying agents and the like. Such formulations and formulating is described in Remingtons's Pharmaceutical Sciences (18 th Edn), Mack Publishing CO, Pennsylvania, USA.
EXAMPLES
[0000] A) Preparation of Topical Medicaments Using Biologically-active Oils
[0086] Examples of creams for topical application were prepared according to the following protocols:
Formulation 1 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 52.475 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.350 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 30.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 5.000 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Cerasynt 840 ™ PEG-20 stearate 1.000 Ceraphyl 230 ™ Di-isopropyl adipate 4.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 0.875 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
1. In phase A combine water and glycerol, and mix well 2. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed. Then heat to 75-80° C. while stirring, for at least 30 minutes. 3. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 4. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 5. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 6. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 7. Add phase D to batch and mix until uniform. 8. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to the amounts of preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0098] (d) Stabileze QM, Cerasynt 840, Ceraphyl 230, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
Formulation 2 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 51.950 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.500 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 25.000 Neem seed oil Neem seed oil 4.000 Tea tree oil Tea tree oil 1.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 5.000 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Cerasynt 840 ™ PEG-20 stearate 1.000 Ceraphyl 230 ™ Di-isopropyl adipate 4.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH 1.250 Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
9. In phase A combine water and glycerol, and mix well 10. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed. Then heat to 75-80° C. while stirring, for at least 30 minutes. 11. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 12. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 13. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 14. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 15. Add phase D to batch and mix until uniform. 16. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0110] (d) Stabileze QM, Cerasynt 840, Ceraphyl 230, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
Formulation 3. COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 46.425 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.650 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 25.000 Neem seed oil Neem seed oil 5.000 Cerasynt 945 ™ Glyceryl stearate & Laureth 23 6.000 Cerasynt 840 ™ PEG-20 stearate 4.000 Ceraphyl 230 ™ Di-isopropyl adipate 5.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 1.625 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturig Procedure
17. In phase A combine water and glycerol, and mix well 18. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed. Then heat to 75-80° C. while stirring, for at least 30 minutes. 19. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 20. Add phase B to phase A and homogenise for 15 minutes, then turn off the heat source. 21. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes without further heating. 22. Remove homogeniser and thoroughly mix with cooling to 38-40° C. 23. Add phase D to batch and mix until uniform. 24. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to the amount of preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0122] (d) Stabileze QM, Cerasynt 945, Cerasynt 840, Ceraphyl 230, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
Formulation 4 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 51.475 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.350 anhydride) decadiene crosspolymer PHASE B Oil Biologically active oil 25.000 Neem seed oil Neem seed oil 4.000 Tea tree oil Tea tree oil 1.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 5.000 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Cerasynt 840 ™ PEG-20 stearate 1.000 Ceraphyl 230 ™ Di-isopropyl adipate 4.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 0.875 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
25. In phase A combine water and glycerol, and mix well 26. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed. Then heat to 75-80° C. while stirring, for at least 30 minutes. 27. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 28. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 29. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 30. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 31. Add phase D to batch and mix until uniform. 32. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0134] (d) Stabileze QM, Cerasynt 840, Ceraphyl 230, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
Formulation 5 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 51.475 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.350 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 25.000 Neem seed oil Neem seed oil 4.000 Tea tree oil Tea tree oil 1.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 5.000 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Cerasynt 840 ™ PEG-20 stearate 1.000 Eucalyptus oil Eucalyptus oil 4.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 0.875 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
33. In phase A combine water and glycerol, and mix well 34. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 35. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 36. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 37. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 38. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 39. Add phase D to batch and mix until uniform. 40. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0146] (d) Stabileze QM, Cerasynt 840, Ceraphyl 230, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
FORMULATION 6 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 53.525 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.350 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 20.000 Neem seed oil Neem seed oil 4.000 Tea tree oil Tea tree oil 1.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 6.250 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Vitamin E acetate Vitamin E acetate 0.200 Ceraphyl 230 ™ Di-isopropyl adipate 7.500 PHASE C 10% w/v NaOH Sodium hydroxide 0.875 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
41. In phase A combine water and glycerol, and mix well 42. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 43. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 44. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 45. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 46. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 47. Add phase D to batch and mix until uniform. 48. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0158] (d) Stabileze QM, Ceraphyl 230, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
FORMULATION 7 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 53.525 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.350 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 20.000 Neem seed oil Neem seed oil 4.000 Tea tree oil Tea tree oil 1.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 6.250 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Ceraphyl 140A ™ Isodecyl Oleate 7.5 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 0.875 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
49. In phase A combine water and glycerol, and mix well 50. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 51. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 52. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 53. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 54. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 55. Add phase D to batch and mix until uniform. 56. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0170] (d) Stabileze QM, Ceraphyl 140A, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
FORMULATION 8 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 53.525 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.350 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 25.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 6.250 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Ceraphyl 140 ™ Isodecyl Oleate 5.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 0.875 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
57. In phase A combine water and glycerol, and mix well 58. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 59. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 60. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 61. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 62. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 63. Add phase D to batch and mix until uniform. 64. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0182] (e) Stabileze QM, Ceraphyl 140A, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
FORMULATION 9 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 51.475 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.400 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 20.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 5.000 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Ceraphyl 140A ™ Isodecyl Oleate 5.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 1.000 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
65. In phase A combine water and glycerol, and mix well 66. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 67. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 68. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 69. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 70. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 71. Add phase D to batch and mix until uniform. 72. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0194] (d) Stabileze QM, Ceraphyl 140A, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
FORMULATION 10 COMPO- SITION DESCRIPTION (% w/w) PHASE A Water Water 67.950 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/maleic 0.500 anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 10.000 Vitamin E Vitamin E 2.000 Vitamin C Palmitate Vitamin C Palmitate 3.000 Prolipid 141 ™ Emulsifier blend of stearic acid, behenyl 4.000 alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Ceraphyl 140A ™ Isodecyl Oleate 5.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 1.250 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
73. In phase A combine water and glycerol, and mix well 74. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 75. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80° C. 76. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 77. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 78. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 79. Add phase D to batch and mix until uniform. 80. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required.
[0206] (d) Stabileze QM, Ceraphyl 140A, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
FORMULATION 11 COMPOSITION DESCRIPTION (% w/w) PHASE A Water Water 57.300 Glycerol Glycerol 3.000 Disodium EDTA Disodium EDTA 0.100 Stabileze QM ™ Poly(methyl vinyl ether/ 0.400 maleic anhydride) decadiene crosspolymer PHASE B Oil Biologically-active oil 20.000 Prolipid 141 ™ Emulsifier blend of stearic 5.000 acid, behenyl alcohol, glycerol-monostearate, lecithin, C12-C16 alcohols and palmitic acid Methyl Salicylate Methyl Salicylate 10.000 Vitamin E acetate Vitamin E acetate 0.200 PHASE C 10% w/v NaOH Sodium hydroxide 1.000 Water Water 2.000 PHASE D Liquapar Optima ™ Phenoxyethanol, methylparaben, 1.000 Isopropylparaben, isobutylparaben butylparaben Total 100.000
Manufacturing Procedure
81. In phase A combine water and glycerol, and mix well 82. Sprinkle Stabileze QM™ into the pre-mixed solution with stirring at room temperature, until uniformly dispersed, then heat to 75-80° C. while stirring, for at least 30 minutes. 83. In a separate vessel, combine ingredients of phase B; mix and heat to 75-80°C. 84. Add phase B to phase A and homogenise for 3-5 minutes, then turn off the heat source. 85. Add phase C into homogenate of phases A & B and then homogenise for 3-5 minutes with no further heating. 86. Remove homogeniser and thoroughly mix and while cooling to 38-40° C. 87. Add phase D to batch and mix until uniform. 88. Adjust for water loss and mix until uniform.
Notes
(a) Adjustments to preservative may have to be made after challenge testing. (b) Small adjustments may have to be made to the Stabileze QM™ concentration to give correct viscosity depending on the application. (c) Small adjustments in composition will have to be made, to allow for fragrance if required. (d) Stabileze QM, Prolipid 141 and Liquapar Optima are trade marks of International Specialty Products, Inc. 1361 Alps Road Wayne N.J. 07470
B) Oral Formulations Containing Biologically Active Oils:
1. Hard gel capsules (0.95 mL) made of gelatine or equivalent polymer containing approximately 0.9 gm of oil containing 0.1% Tocopheryl acetate. 2. Hard gel capsules (0.95 mL) made of gelatine or equivalent polymer containing 0.50 gm of oil dispersed in macadamia oil or equivalent. 3. Soft gel capsules (100 μL up to 1.0 mL capacity) made from gelatine or equivalent polymer containing from 100 μL up to 1.0 mL of oil with 0.1% anti-oxidant added if required. 4. Soft gel capsules (100 μL up to 1.0 mL capacity) made of gelatine or equivalent polymer containing from 10 mg up to 1000 mg of extract from the oil containing if required an anti-oxidant and another oil for example macadamia oil, soybean oil or equivalent. 5. Soft gel suppositories as for 3 & 4 above. 6. Syrups and lotions made from oil and extracts with the addition of other oils such as olive, macadamia and flavours such as raspberry, strawberry, banana and with the addition of anti-oxidants if required. Dose by spoon or syringe. 7. Oral dose 5.0 mL oil by spoon or syringe.
C) In vivo Rat Model Test Procedures Used to Analyse the Biological Activity of Various Animal and Plant Oils and Their Extracts
1. Anti-inflammatory efficacy was measured in rats developing the adjuvant-induced polyarthritis, the test agents being given either transdermally or orally from the time the arthritis was first expressed. Synergistic activity with low-dosed steroid was measured either in i) rats with fully established adjuvant arthritis or ii) rats with chronic paw oedema induced by injecting 0.5 mg zymosan (in 0.2 mL saline) then waiting 3 hours for the acute oedema to peak (associated with histamine/serotonin release) and measuring residual paw swelling 21-45 hours later. For transdermal administration, oils were diluted with 0.15 vol of cineole to facilitate skin penetration and applied once daily to the shaved dorsal skin (6 cm 2 ) with brief rubbing. (See Tables 1 and 2 below). 2. Co-arthritigenic activity was measured in Dark Agouti rats by first dispersing finely-ground heat-killed Mycobacterium. tuberculosis in test oils (10 mg/kg) and then injecting 0.1 mL into the tailbase of female Dark Agouti rats. Signs of arthritis were recorded on day 15. Extracts from emu oils were obtained by mixing equal masses of oil and methanol then storing in a cold room or freezer at 0° C. for at least 12 hours, decanting the liquid layer, evaporating the solvent using a rotary film evaporator. Residue remaining in the flask contains the extract. These extracts were first dissolved in jojoba bean oil and diluted with an equal volume of a dispersion of Mycobacterium. tuberculosis (1 0mg/ml)freshly prepared in jojoba bean oil. (See Table 3 below). 3 . Gastroprotectant activity was ascertained in a) disease stressed (untreated) polyarthritic female Dark Agouti or Wistar rats and b) normal Dark Agouti or Wistar rats which had been fasted overnight and injected with the cholinergic drug, methacholinehydrochloride (5 mg/kg i.p.). Test materials were emulsified with 0.04% v/v Tween-20 using a Vortex homogeniser, then co-dosed with a dispersion of OTC ibuprofen (NUROFEN) 55 mg/kg used as the gastrotoxin. The stomachs were removed 2.5 hours later, briefly rinsed in saline and scored for number and severity of macroscopic haemorrhagic lesions in the gastric mucosa. (See Tables 4 and 5 below). 4. Synergistic activities of emu and macadamia oils with corticosteroids for suppressing Zymosan-induced paw oedema in rats. A single treatment of whole oil, or extract, plus either P=prednisone 2.5 mg/kg or D=dexamethasone 0.1 mg/kg in Tween-20 was administered orally 3 hours after injecting 0.5 mg zymosan into each rear paw. Data are the relative reduction in paw swelling compared with controls treated with olive oil only, expressed as percentage inhibition. (see Table 6 below). 5. For in vitro tests, oils were processed to remove the bulk of the triglycerides using solvent extraction at low temperature or solid-phase extraction in accordance with normal laboratory procedures. For in vivo tests, the oils were filtered at 22° C. to remove solids, varying from 5-45% by weight. Exceptionally stiff samples were diluted either with 0.1 volume n-octanol or up to 0.5 volumes isopropyl myristate to help ‘liquefy’ them, these solvents being inert vehicles for the assays described.
Note: All Mycobacterium. tuberculosis Used is Finely Ground and Heat Killed Prior to Use.
Results
1. Wistar rats were injected with 0.8 mg Mycobacterium. tuberculosis in 0.1 mL squalene in tailbase (day 0). Treatments with biologically active oils were given either A) transdermally on days 10-13 only (4 rats/gp) or B) orally on days 15-17 together with prednisone (2.5 mg/kg, 3 rats/gp)
[0234] The changes in arthritic signs are shown below. An increase in weight is good, a decrease indicates possible toxicity. The lower the arthritic score, the better:
[0235] Note: For information on oils refer to chromatogram number and table 6 which contains process conditions.
[0236] Process conditions and chromatograph for each sample in Tables 1 to 8 are summarised in Table 11. The corresponding chromatograms are numbered 1 to 32. As an example, emu-type 2 oil in Table 3 was obtained according to the process conditions set out in line 4 of Table 11 (sample code Type 2) and the biological activity of the sample is shown in chromatogram 4.
TABLE 1 Mean Changes in A. Treatment Arthritic Signs (Days 10→14) (transdermal) Rear paw Forepaw ΔWeight Arthritis Sample Dose/kg/day thickness inflammation gm Score Olive Oil - Control 2.0 mL 0.89 mm 2+ +05 2+ Emu-A Chrom. 1. 0.5 mL 0.15 mm 0.5+ +14 0.5+ Emu-C Chrom. 2. 1.0 mL 0.37 mm 1.4+ +18 1+ Emu-Kalaya Chrom. 3. 0.5 mL 0.08 mm −0.2+ +05 0.2+
[0237]
TABLE 2
B. Treatment (Oral)
Mean Changes in Arthritic Signs (Days 15→18)
Dose/
Rear paw
Forepaw
ΔWeight
Arthritis
Sample
kg/day
thickness
Tail thickness
inflammation
gm
Score
Olive Oil
2.0 mL
0.0 mm
+0.42 mm
0.6+
+02
0.5+
(OO) only - control
Prednisone
with:
Olive Oil
2.0 mL
−0.05 mm
0.15 mm
0.3+
+03
0
Emu-A
2.0 mL
−0.59 mm
−0.82 mm
−0.8+
0
−0.9+
Chrom. 1
Emu-C
2.0 mL
+0.13 mm
−0.14 mm
0.8+
−01
0.3+
Chrom. 2
[0238] TABLE 3 Arthritigenic activity of some emu/other oils Oils were admixed with finely ground heat-killed M. tuberculosis (10 mg/mL) and 0.1 mL injected into the tail base of female Dark Agouti rats. Dispersions with jojoba bean oil contained a final concentration of only 5 mg/mL M. tuberculosis . Signs of arthritis were scored on day 15 for groups of 3 rats. Mean values for Rear paw Arthritis Test Oil swelling ΔWeight Score Olive Oil 1.22 mm +01 2.3+ Lard Oil (pig) 1.03 +14 2.3+ Emu-A Chrom. 1 0.23 +08 0.5+ Emu-C Chrom. 2 0.73 −10 2+ Emu-Kalaya Chrom. 3 0.08 +21 0.7+ Emu-Type 2 Chrom. 4 0.20 +12 0.5+ Jojoba Bean 1.24 +02 2.8+ with extr. Emu-A (5 mg/rat) 0.23 +11 0.7+ with extr. Emu-C (5 mg/rat) 0.92 +07 1.5+ with extr. Emu-Ka (5 mg/rat) 0.08 +11 0.3+ with extr. Emu-Ka (10 mg/rat) 0.09 +20 0.5+
Tables 4/5: Gastroprotective Activity of Some emu Oils in Rats
[0239] Gastro-irritant=55 mg/kg ibuprofen given orally to animals fasted overnight, together with test emulsions=0.4 mL oil/kg prepared with 0.04% v/v Tween-20 along with or without methacholine given i.p.
[0240] A. In disease-stressed female Wistar or Dark Agouti rats with fully developed polyarthritis (on or after day 15), without methacholine.
TABLE 4 Gastric lesion indices in Treatment Wistar rats n = 3/gp Dark Agouti rats n = 4/gp Tween-20 only 32 44 Emu-A Chrom. 1 07 22 Emu-C Chrom. 2 21 51 Emu-Kalaya Chrom. 3 not tested 27
[0241] B. In normal rats stimulated with Beta-methacholine (5 mg/kg in Wistar rats or 8 mg/kg in Dark Agouti rats).
TABLE 5 Gastric lesion indices in Wistar rats Dark Agouti Treatment n = 3/gp rats n = 3/gp Tween-20 only 17 52 Emu-A Chrom. 1 05 17 Emu-C Chrom. 2 19 39 Emu-Kalaya Chrom. 3 05 23 Olive oil (OO) 19 31 Extr.A = 50 mg/kg in OO 06 10
[0242] TABLE 6 Synergistic activities of emu and macadamia oils with corticosteroids for suppressing Zymosan-induced paw oedema in rats. A single treatment of whole oil, or extract, plus either P = prednisone 2.5 mg/kg or D = dexamethasone 0.1 mg/kg in Tween-20 was administered orally 3 hours after injecting 0.5 mg zymosan into each rear paw. Data are the relative reduction in paw swelling compared with controls treated with olive oil only, expressed as percentage inhibition. Wistar rats Dark Agouti rats Treatment Dose/kg Day 1 Day 2 Day 1 Day 2 P + olive oil (OO) 2 mL 4% 1% 15% 2% P + Emu-A Chrom. 1 2 mL 52 81 56 63 0.5 43 52 P + Emu-C Chrom. 2 2 mL −05 −16 −14 −12 P + Lyprinol in OO 20 mg 57 31 65 66 D + olive oil (OO) 2 mL 05 0 D + Emu-A Chrom. 1 2 mL 77 40 D + Emu-C Chrom. 2 2 mL 22 −15 D + Lyprinol in OO 20 mg 56 50 P + Olive oil (OO) 2.0 mL 0 P + Macadamia-19 1.6 mL 1 Chrom. 30 P + Macadamia-20 1.6 mL 41 Chrom. 31 P + Oleic acid (90%) 2.0 mL −11 P + Isostearic acid 2.0 mL 39 (comm.) P + Lyprinol in OO 20 mg 46
D) In-vitro LOX Assays of Several Different Oil Samples
Neutrophil 5-Lipoxygenase Pathway
Overview
[0243] Arachidonic acid is converted into eicosanoids (or prostanoids) by two major pathways—the 5-lipoxygenase pathway, which leads to the formation of leukotrienes, and the cyclo-oxygenase pathway which leads to the formation of prostaglandins and thromboxanes. Some, but not all, of the products of both of these pathways have potent pro-inflammatory properties. For example, LTB 4 is a very potent chemotactic agent, and its peptido-metabolites, LTC 4 , LTD 4 and LTE 4 , which were originally known as “slow reacting substance of anaphylaxis” or SRS-A, are potent bronchoconstrictor agents.
[0244] Many of the currently used anti-inflammatory drugs, in particular the non-steroidal anti-inflammatory drugs (NSAIDS), function via the inhibition of the cyclo-oxygenase pathway. More recently, considerable effort around the world has focused on the development of inhibitors of the lipoxygenase pathway, or of dual inhibitors that block both pathways.
[0245] The principal steps of the 5-lipoxygenase pathway of these cells is shown in FIG. 3 . In this pathway, arachidonic acid (AA), from membrane phospholipids, is released via the action of phospholipase A 2 (PLA 2 ). This AA is then substrate for the first enzyme in the pathway—5 lipoxygenase, which converts it to 5-hydroperoxyeicosatetraenoic acid (5-HPETE). 5-HPETE is then converted enzymatically to either 5-hydroxyeicosa-tetraenoic acid (5-HETE) by glutathione peroxidase, or to leukotriene A 4 (LTA 4 ) by LTA 4 synthase. LTA 4 is then converted either non-enzymatically to the all trans isomers of LTB 4 , or hydrolysed by LTA 4 hydrolase to leukotriene B 4 (LTB 4 ). Human PMN do not significantly metabolise LTB 4 any further, although other cells, such as eosinophils convert it to the potent vasoconstrictor peptido-leukotrienes, SRS-A.
[0000] The Lipoxygenase Pathways (Leukotrienes and HETE) Assay
[0246] The HPLC assay readily quantifies 5-HETE, 12-HETE, LTB 4 , and the two all trans-isomers of LTB- 4 , and thus gives quantitative data on the relative activities of the enzymes in the 5-lipoxygenase of neutrophils, as well as data on the 12-lipoxygenase pathway of platelets. Thus it is an ideal system to test potential inhibitors of these pathways.
[0247] The effects of inhibitory compounds may be tested on isolated human PMN and platelets, in which the pathways are activated by treating the PMN or platelets with arachidonic acid and the calcium ionophore A 23187 . The addition of arachidonic acid eliminates the PLA- 2 step, and provides high levels of substrate for the pathway. Furthermore, such activation is known to maximally drive the pathway to produce the greatest synthesis of all the metabolites, and thus is also the least sensitive to inhibition. Hence, compounds that do inhibit the pathway activated in this fashion are potentially potent inhibitors.
Preparation of Test Samples
[0248] All samples were dissolved in ethanol to give stock solutions of 10 mg/mL. Two further dilutions of each stock solution were made in ethanol at 5 and 1 mg/mL, making 10 test samples in all.
[0249] 10 μL of each of the diluted stocks was added to 1000 μL of PMN suspension in Hank's Buffer, to give final test concentrations of 5, 10 and 50 ug/mL as required for the analysis.
Preparation of Human Neutrophils (PMN)
[0250] 1. Up to 100 mL of blood was taken from a normal volunteer and anticoagulated with EDTA. Two mL of 4.5% EDTA in water was mixed with each 10 mL of blood.
[0251] 2. A further 2 mL of 6.0% Dextran T500 was added to each of the 12 mL mixtures in 1, and placed in a water bath at 37° C., to sediment the red blood cells.
[0252] 3. Following sedimentation in 2, the supernatant was carefully laid over 5 mL of Percoll, density 1.070. This was then spun at 500 g for 35 mins.
[0253] 4. All the cells (PMN and remaining RBC) below the Percoll interface were removed with a plastic pipette and diluted at least 3-fold with Ca 2+ /Mg 2+ -free Dulbecco's phosphate buffer, and centrifuged at 600 g for 10 mins.
[0254] 5. Following 4, the supernatant was carefully aspirated, and the pellet gently mixed with 1 mL of Ca 2+ /Mg 2+ -free Dulbecco's phosphate buffer by aspiration/deaspiration into a 1 ml plastic disposable pipette. A further 40 mL of Ca 2+ /Mg 2+ -free Dulbecco's phosphate buffer was then added and mixed by inversion. The cell suspension was then centrifuged at 600 g for 10 mins.
[0255] 6. Following centrifugation, the supernatant was removed and the PMN pellet lysed with 10 mL of a 0.2% cold sodium chloride solution for 20 secs, followed by the addition of 10 mL of a 1.6% cold sodium chloride solution, and centrifuged at 600 g for 10 mins.
[0256] 7. Following 6, the PMN pellet was vigorously mixed with 1 mL of Hank's buffer by rapid aspiration/deaspiration into a 1 mL plastic disposable pipette, and then finally suspended in Hank's buffer at 2.4×10 6 PMN/ml (as measured using a Coulter counter), in preparation for the leukotriene assay.
Activation of Leukotriene Pathway
[0257] 1. 1 mL of PMN suspension (2.4×10 6 PMN/ml) was transferred to a 13 mL glass tube (chromic acid washed) and placed in a water bath at 37° C. for 5 min prewarming.
[0258] 2. Following prewarming, at time zero, 10 μL of each test compound in methanol (or equivalent volumes of methanol as control) was added to quadruplicate tubes over a 20 sec period.
[0259] 3. At 5 min, 5 mL of 2 mM arachidonic acid (10 μM final) was added (4 tubes/20 secs).
[0260] 4. At 10 min, 5 ml of 1 mM calcium ionophore (A 23187 ) (5 μM final) was added (4 tubes/20 secs).
[0261] 5. At 15 min the reaction was terminated by the addition of 100 μL 100 mM citric acid. This lowers the pH of the aqueous phase to less than 3, which is necessary for the extraction of the leukotrienes into the organic phase.
[0262] 6. The pH of several samples was checked to ensure pH <3.0. (This is important).
[0263] 7. 40 ng Prostaglandin B2 and 166 ng 15-HETE were added to each tube as the internal standard for LTB4 and 5-HETE respectively, and samples were mixed.
[0264] 8. For Standard Curves LTB4 [1 ng/μl] (for a standard curve in the range 0-50 ng) and 5-HETE [5ng/μL] (standard curve range 0-250 ng) were added to tubes containing 1 mL PMN, 100 μL of 100 mM citric acid and 40 ng PGB 2 and 166 ng 15-HETE.
[0265] 9. All tubes were vortexed.
[0266] 10. 5 mL chloroform/methanol (7:3) was added and the tubes vortexed vigorously for 30 secs, then centrifuged for 10 min at 2000 rpm.
[0267] 11. Approx. 3.5 mL of the lower chloroform layer (containing the extracted leukotrienes and hydroxy acids (HETES), as well as the internal standards) was transferred to a 3 mL borosilicate glass tube and the chloroform evaporated in a Savant centrifugal evaporator, under vacuum, at room temperature.
[0268] 12. The samples were reconstituted in 100 μL of the LTB 4 mobile phase, vortexed and transferred to Waters low volume inserts for injection (usually <25 μl).
[0269] 13. The HPLC was setup for the LTB 4 conditions, and all the samples assayed for LTB 4 and the all trans isomers of LTB 4 .
[0000] HPLC Assay for Leukotrienes and Hydroxy Acids
[0000] Mobile Phases
[0000]
5 LTB 4 Assay: 70% Methanol/30% H 2 O/0.08% Acetic Acid (pH adjusted to 6.2 with ammonium hydroxide).
5-HETE Assay: 80% Methanol/20% H 2 O/0.08% Acetic Acid (pH adjusted to 6.2 with ammonium hydroxide).
[0272] HPLC Conditions
Wavelength: 270 nm (LTB 4 ), 234 nm (5-HETE) Analysis: Water's Millennium Flow Rate: 1 mL/min Column and Guard Pak: C 18 Nova Pak
LTB 4 ASSAY
[0273] Retention Times
Prostaglandin B 2 - 4.6 min 6-trans-leukotriene B 4 - 6.6 min 6-trans-epi-leukotriene B 4 - 7.4 min Leukotriene B 4 - 8.7 min
Full Chemical Names of LTB 4 and its 6-Trans Isomers
Leukotriene B 4 : (5S,12R)-Dihydroxy-(Z,E,E,Z)-6,8,10,14-eicosatetraenoic acid. 6-trans-Leukotriene B 4 : (5S,12R)-Dihydroxy-(E,E,E,Z)-6,8,10,14-eicosatetraenoic acid. 6-trans-12-epi-LeukotrieneB 4: (5S,12S)-Dihydroxy-(E,E,E,Z)-6,8,10,14-eicosatetraenoic acid
5-Hete Assay
[0277] Retention times
15-HETE-6.3 min 5-HETE-8.5min
[0280] Full Chemical Names
15-HETE: 15(S)-Hydroxy-(Z,Z,Z,E)-5,8,11,13-eicosatetraenoic acid 5-HETE: 5(S)-Hydroxy-(E,Z,Z,Z)-6,8,11,14-eicosatetraenoic acid
Effect of Emu Oil Methanol Extracts and pure 12-methyl tetradecanoic acid (12-MTA) on Leukotriene Synthesis
Expressed as a Percentage of the Methanol Control
[0283] TABLE 7 Test Material Dilution Isomer 1 Isomer 2 LTB 4 5-HETE Control 100 ± 22 100 ± 22 100 ± 4 100 ± 4 Emu-Type 2 Chrom. 4 50 μg/mL 0 0 11 ± 8 10 ± 5 Emu-Type 2 Chrom. 4 10 μg/mL 88 ± 12 71 ± 11 74 ± 6 76 ± 16 Emu-Type 2 Chrom. 4 5 μg/ml 94 ± 12 99 ± 13 84 ± 10 102 ± 2 Emu-Type 2* Chrom. 4 50 μg/mL 23 ± 3 20 ± 4 17 ± 11 16 ± 11 Emu-Type 2* Chrom. 4 10 μg/mL 78 ± 6 76 ± 7 80 ± 4 78 ± 7 Emu-Type 2* Chrom. 4 5 μg/mL 95 ± 9 96 ± 8 88 ± 2 90 ± 7 Emu-Type-B Chrom. 24 50 μg/mL 0 0 0 4 ± 2 Emu-Type-B Chrom. 24 10 μg/mL 82 ± 14 86 ± 14 88 ± 9 66 ± 9 Emu-Type-B Chrom. 24 5 μg/mL 110 ± 11 137 ± 9 95 ± 8 92 ± 1 12-MTA 50 μg/mL 0 0 0 0 12-MTA 20 μg/mL 0 0 0 2 ± 4 12-MTA 10 μg/mL 59 ± 14 68 ± 14 70 ± 17 46 ± 11 12-MTA 5 μg/mL 101 ± 12 97 ± 9 101 ± 12 65 ± 3 12-MTA 2 μg/mL 73 ± 13 60 ± 17 84 ± 5 55 ± 9 *Prior to extraction the original oil sample was treated by passing nitrogen gas at high flow rate through oil heated at 135° C. for two hours with rapid stirring, to remove volatile compounds.
Effects of Fatty Acid Methyl Ester of emu oil, Methanol Extracts of emu and Ostrich Oil Produced by Fungal Inoculation and Incubation on Leukotriene Synthesis
Expressed as a Percentage of the Methanol Control
[0284] TABLE 8 Test Material Dilution Isomer 1 Isomer 2 LTB 4 5-HETE Control 100 ± 9 100 ± 10 100 ± 6 100 ± 5 Fatty acid methyl ester of emu oil* 50 μg/mL 7 ± 0.5 0 8 ± 1 6 ± 2 Fatty acid methyl ester of emu oil* 10 μg/mL 103 ± 9 103 ± 8 95 ± 6 105 ± 4 Emu oil-WB methanol extract 50 μg/mL 4 ± 0.5 0 0 23 ± 4 Chrom. 21 Emu oil-WB methanol extract 10 μg/mL 61 ± 2 65 ± 2 80 ± 3 85 ± 3 Chrom. 21 Ostrich oil methanol extract 50 μg/mL 9 ± 2 14 ± 3 22 ± 6 21 ± 8 Chrom. 22 Ostrich oil methanol extract 10 μg/mL 56 ± 12 74 ± 17 65 ± 11 83 ± 13 Chrom. 22 *Fatty acid methyl ester (FAME) of emu oil sample A, Chromatogram 1.
Results and Discussion
[0285] The data shows that all three samples in table were potent inhibitors of the 5-LOZ pathway. The data are compared to 12-methyl tetradecanoic acid which showed 100% inhibition as low as 20 μg/mL.
[0286] With respect to samples in Table 8, FAME sample was the least effective, where as Emu oil-WB and Ostrich oil samples are approximately the same as the three samples in Table 7. This confirms that the process for the production of biologically-active oils may be reproduced using different lipid substrates etc.
[0000] E) In-vitro Prostaglandin PGE 2 (COX Pathways) Assay Oil Samples
[0287] This assay was performed using Cayman chemicals Prostaglandin E 2 EIA Kit-Monoclonal, according to kit protocol. Each sample was assayed at three dilutions in duplicate. As can be seen from Table 9 the inhibition of the PGE 2 response to aspirin (50 μM) was around 72.6% of the control value. In particular the two samples produced dose dependent inhibition of secreted PGE 2 from the mouse fibroblast cell line equivalent to or better than aspirin under the test conditions.
TABLE 9 Percent Inhibition of Secreted PGE 2 from 3T3 cells exposed to Oil Extracts Concentration Sample μg/mL % Control DMSO + A23187 100 Aspirin 50 μM 72.6 Emu Oil Extract - P3 Chrom. 3 100 52 Emu Oil Extract - P3 Chrom. 3 20 59 Emu Oil Extract - P3 Chrom. 3 4 84.8 Lyprinol - P10 100 60.9 Lyprinol - P10 20 83.6 Lyprinol - P10 4 84.6
F) Examples of Therapeutic Activity
[0288] 1) Patient suffering from ulcerative colitis for seven years had experienced chronic diarrhoea and daily rectal bleeding. Patient ingested 5 mL of fungi-derived biologically-active emu oil twice daily. All anal bleeding associated with the ulcerative colitis disappeared after 2 months. This patient has also responded to fungi-derived biologically-active ostrich oil.
[0289] 2) Patient suffering chronic pain from intestinal and duodenal ulcers ingested 5 mL of fungi-derived biologically-active emu oil twice daily and pain has ceased. Patient also observed that his unstable diabetes became more responsive to the insulin resulting in a reduction of dosage required.
[0290] 3) Patient diagnosed with Crohn's disease 5 years ago and was suffering ongoing abdominal pain, diarrhoea or constipation, rectal bleeding, cold sweats and lethargy. After weeks ingesting 5 mL of fungi derived biologically-active emu oil twice daily. The patient's Crohn's disease is in remission (this has been confirmed by medical tests) with no further abdominal pains, diarrhoea or constipation.
[0291] 4) Patient diagnosed with breast cancer, had lumpectomy, radiation and chemotherapy. Topical application of cream produced from fungi-derived biologically-active oil applied three times daily which reduced pain and inflammation in the breast.
[0292] 5) Patient is a 54 year old Caucasian male with a 10 year history of mild to moderate asthma, which was controlled with 400 ug twice daily of beclomethasone and either salbutamol or turbutamine bronchodilator inhalers where needed. This was inadequate to control viral induced asthma following winter infections where oral prednisone at 5 mg/day was required to reduce chronic wheezing and coughing to an acceptable level. The patient was administered 8 g/day of fungi-derived biologically-active emu oil in divided doses-4 g morning and night. Within 3 weeks all asthma symptoms reduced, and improvement continued following cessation of aerosol steroids. After 2 months on the oil, the patient controlled all symptoms of asthma with 4 g/day of the oil and no other medication. In addition, the administration of the oil has reduced the need for LOSEC to be taken for the patient's gastric reflux.
[0293] 6) Patient is a 62 year old female with a 51 year history of chronic asthma (Classified as chronic airways limited), which was controlled by 10-50 mg/day of oral prednisone, 900 mg/day of neulin, plus frequent use of ventolin/atrovent puffers and nebules was required to control chronic wheezing and coughing to an acceptable level. The patient was administered 6ml of fungi-derived biologically-active emu oil in divided doses, 3 mL morning and night. The patient has been on this dose of oil for 11 months and this has virtually eliminated the wheezing noise, reduced the level of coughing, plus the level of prednisone has been reduced to 5 mg/day. Also use of puffers and nebules has been reduced. No longer needs to take Losec for gastric reflux. By increasing the emu oil to 9 mL/day, three 3 mL doses/day with a slight increase in prednisone to 10 mg/day any asthma attacks can be controlled (the oil synergistically increases activity of prednisone, as confirmed by a rat model). Her daily life style has been greatly improved since commencing use of this oil.
[0294] 7) Patient is an eurasian Male patient 23 years of age, diagnosed by colonoscopy, and is prescribed 40 mg prednisone daily reduced 5 mg every two weeks, 2 grams of mesalamine daily. 6 weeks later after blood results received, the patient is hospitalised and administered 7 days of hydrocortisone IV, lost 4 kg in weight, heads of hip bones began to die off as a resulting side effect of the medication. The patient is prescribed post-hospital medication of:
100 mg Imuran daily (intended four year treatment) 50 mg of prednisone daily (reducing 5 mg every two weeks). The patient then began taking 5 ml of oil (batch 365) three times a day, and ceased all other medication within one month from starting on the oil. His medical problems continued to reduce in severity. Three months after starting on the oil the patient was instructed to take extract of oil (batch 365), two teaspoons daily, and has experienced no chronic symptoms in four months. The patient's health continues to improve (digestive system, stamina, fitness etc), with a weight gain of 5 kg. Cumulative C Reactive Protein reduced over a period of six months from 65.1 to 5.3 mg/L, Range (0.0-5.0) mg/L. The patient's results are summarised in Table 10 below.
[0297] CRP and ESR Results
TABLE 10 C Reactive Protein ESR (High Sensitivity) Range Date Range (0.0-5.0) mg/L (0-20) mm/hr 07/08/03 65.1 9/09/03 25.9 21/10/03 33.5 09/12/03 5.2 4 10/02/03 4.9 3 13/04/03 5.3 1
[0298]
TABLE 11
Chromatogram
Sample
Lipid
Fungal
Temp
Time
Number
Code
Substrate
Mixture
Humidity
(° C.)
(days)
1
A
emu
Rhodotorula mucilaginosa , Crytococcus albidus , Trichosporon
High
10-12
128
pullulans , Mucor spp, Epicoccum purpurescens , Rhizopus
stolonifer , Penicillium chrysogenum , Nigrospora sphaerica ,
Chaetomium globosum , Alternaria alternata
2
C
emu
No fungi
High
10-12
128
3
Kalaya
emu
Rhodotorula mucilaginosa , Crytococcus albidus , Trichosporon
Medium
10-15
128
pullulans , Mucor spp, Epicoccum purpurescens , Rhizopus
stolonifer , Penicillium chrysogenum , Nigrospora sphaerica ,
Chaetomium globosum
4
Type 2
emu
Rhodotorula mucilaginosa , Crytococcus albidus , Trichosporon
High
15-20
128
pullulans , Mucor spp, Epicoccum purpurescens , Rhizopus
stolonifer , Penicillium chrysogenum , Nigrospora sphaerica ,
Chaetomium globosum
5
E113
emu
Mucor BB14
High
20
21
6
E115
emu
Mucor BB18
High
20
21
7
E108
emu
Penicillium chrysogenum
High
20
21
8
E109
emu
Rhodotorula mucilaginosa
High
20
21
9
E110
emu
Crytococcus albidus
High
20
21
10
E111
emu
Trichosporon pullulans
High
20
21
11
E112
emu
Trichosporon pullulans , Rhodotorula mucilaginosa ,
High
20
21
Crytococcus albidus
12
E116
emu
Mucor Black
High
20
21
13
E117
emu
All Mucor spp
High
20
21
14
E118
emu
Trichosporon pullulans , Rhodotorula mucilaginosa , Crytococcus
High
20
21
albidus , Penicillium chrysogenum , Mucor BB14, Mucor BB16,
Mucor BB18, Mucor Black
15
E104
emu
Mucor BB14, Mucor BB16, Mucor BB18, Mucor Black
High
20
21
16
E119
emu
Nil
High
20
21
17
L17
lamb
Mucor Black
High
20
24
18
E90
lamb
Penicillium chrysogenum , Mucor BB12, Mucor BB13, Mucor
Low to
20
7
BB15, Mucor Black
medium
19
E60
macadamia
Crytococcus albidus
Low
20
14
20
E80
macadamia
Crytococcus albidus
Low
20
21
21
TLWB1
emu
Rhodotorula mucilaginosa , Crytococcus albidus , Trichosporon
Medium
10-12
14
pullulans , Mucor spp, Epicoccum purpurescens , Rhizopus
stolonifer , Penicillium chrysogenum , Nigrospora sphaerica ,
Chaetomium globosum , Alternaria alternata
22
TLOSTF
ostrich
Rhodotorula mucilaginosa , Crytococcus albidus , Trichosporon
Medium
10-12
14
pullulans , Mucor spp, Epicoccum purpurescens , Rhizopus
stolonifer , Penicillium chrysogenum , Nigrospora sphaerica ,
Chaetomium globosum , Alternaria alternata
23
ZB2
beef
Trichosporon pullulans , Rhodotorula mucilaginosa , Crytococcus
Low
20
63
albidus , Penicillium chrysogenum , Mucor BB14, Mucor BB16,
Mucor BB18, Mucor Black
24
Type-B
emu
Rhodotorula mucilaginosa , Crytococcus albidus , Trichosporon
Medium
10-12
28
pullulans , Mucor spp, Epicoccum purpurescens , Rhizopus
stolonifer , Penicillium chrysogenum , Nigrospora sphaerica ,
Chaetomium globosum , Alternaria alternata
25
M11
Macadamia
Chaetomium sp
medium
20
35
26
M14
Macadamia
Penicillium , Chaetomium , Absidia and Mucoraceous fungi,
medium
20
35
mixed through crushed nuts
27
M14A
Macadamia
Absidia sp
medium
20
35
28
M15
Macadamia
Penicillium , Chaetomium , Absidia and Mucoraceous fungi, fungi
medium
20
35
inoculated on surface of crushed nuts.
29
M16
Macadamia
Mucoraceous fungus
medium
20
35
30
M19
Macadamia
Penicillium , Chaetomium , Absidia and mucoraceous fungi, fungi
high
10
35
inoculated on surface of crushed nuts
31
M20
Macadamia
Penicillium janczewski
medium
20
28
32
M21
Macadamia
Penicillium sclerotiorum
medium
20
28
|
A process for the production of fats or oils and their extracts containing biologically-active chemical compounds from a lipid substrate, the process comprising: a) inoculation of a lipid substrate with fungally derived lipolytic enzymes b) incubating the inoculated substrate for a period of between about 7-120 days at a temperature of between about 4-35° C., at a humidity of between about 75-100%, and C) processing said substrate mixture to obtain a biologically active fat or oil.
| 2
|
This is a divisional of application Ser. No. 08/038,413 filed on Mar. 29, 1994 now U.S. Pat. No. 5,414,034.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a melt extrusion processes, and more particularly relates to melt extrusion processes for making polypropylene fibers or films.
BACKGROUND OF THE INVENTION
Processes for making polymeric fibers and films are known, see U.S. Pat. Nos. Knox, U.S. Pat. No. 4,156,071, issued May 22, 1979, Frankfort et al, U.S. Pat. No. 4,134,882, issued Jan. 16, 1979, Piazza et al., U.S. Pat. No. 3,772,872, issued Nov. 20, 1973, Petrille, et al., U.S. Pat. No. 3,771,307, issued Nov. 13, 1973, Kilian, U.S. Pat. No. 3,002,804, issued Oct. 3, 1961, Coates et al., U.S. Pat. No. 2,957,747, issued Oct. 25, 1960, Hebeler, U.S. Pat. No. 2,604,667, issued Jul. 29, 1952, all of which are incorporated herein by reference, and Great Britain Patent Nos. 903427, published Aug. 15, 1962, 1487843, published Oct. 5, 1977 and 1574305, published Sep. 3, 1986, all of which are incorporated herein by reference. Phosphites are known stabilization additives for polyolefins, see York, U.S. Pat. No. 4,305,866, Lewis, U.S. Pat. No. 4,403,053, issued Sep. 6, 1983 and Valdiserri et al, U.S. Pat. No. 4,302,383, issued Nov. 24 1981, all of which are incorporated herein by reference.
Polyolefin processors are attempting to process polymer at increasing temperatures and with increased shear and work on the polymer. They are also processing polymer which may contain polymerization catalyst residues. The total residual metal content has been decreasing in recent years but the catalyst residue may still be active.
This combination of more abusive processing conditions and the possibility of catalyst residue still being active may lead to difficulties when trying to process the polymers.
Catalyst "neutralizers" are well known in the art and are generally used in most formulations to inhibit corrosion of processing equipment resulting from catalyst residues. Typical examples would be: Ca, Zn, or Mg Stearates, Ca, Zn, or Mg oxides and synthetic hydroftalcite compositions such as a product manufactured and sold by Kyowa as DHT4A. Additionally products such as the Calcium Stearoyl Lactates and Calcium Lactates have been shown to be beneficial in catalyst neutralization as evidenced by reduced corrosion.
In many of the high temperature melt processes such as fiber spinning and film manufacture, screen packs are utilized to remove small particles which may be in the polymer prior to the polymer passing through the small orifices used in fiber and film processes. With the higher processing temperature/high shear applications there is a tendency for some combinations of polymers and additive formulations to be prone to screen pack plugging.
Specifically, it has been discovered, however, that stabilized polyolefin compositions containing residual catalysts, can generate solid byproducts during melt extrusion processes. These solids must be filtered out from the melt stream.
For example, melt stream fiber forming processes and film forming processes or the fiber and/or film forming dies will become clogged or the final articles (films/fibers) will exhibit defects and blemishes. Too much solid generation will lead to frequent filter clogging, referred to as screen pack plugging, which leads to increased processing pressures and reduced process throughput.
Consequently, there is a need for improved polyolefin compositions and improved melt extrusion processes that will exhibit reduced solid byproduct formation and a resulting reduced filter clogging and a reduced increase in processing pressure and improve in throughputs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the process of the present invention for making fibers, and
FIG. 2 is a schematic drawing of the process of the present invention for making films.
SUMMARY OF THE PRESENT INVENTION
The present invention involves an improved polyolefin melt extrusion process that exhibits reduced filter clogging. The process involves (a) forming a polyolefin composition comprising a polyolefin resin, a phosphite stabilizer, a metal salt of a lactic acid and optionally a primary antioxidant, (b) melt extruding the composition through a filter to produce a filtered melt stream, and (c) passing the melt stream through a die to make the plastic article. The utilization of the metal salt of a lactic acid results in reduced filter clogging.
DETAILED DESCRIPTION OF THE INVENTION
The olefin polymers contemplated herein include homopolymers and copolymers of monoolefins, preferably those monoolefins containing 1-4 carbon atoms. Illustrative examples include polyethylene (including low density, high density, ultra high molecular weight and linear low density polyethylene), polypropylene, EPDM polymers, ethylene-propylene copolymers and polyisobutylene. The stabilization of mixtures of any of these olefin polymers and copolymers likewise is contemplated.
Any polypropylene resin melt extrusion process involving polymer filtration can be improved by the process of the present invention, including propylene homopolymers and random or block copolymers of propylene and an a-olefin which contain ethylene or other a-olefin in an amount from 1 to 30 wt. % as well as blends of polypropylene with other olefin polymers and copolymers, such as low and high density polyethylene, ethylene/vinyl acetate copolymer, ethylene/propylene copolymer rubbers and styrene/butadiene block-copolymer rubbers.
Phosphites may be replaced in whole or in part with a phosphonite. The compositions preferably employ a phosphorous containing component selected from the group consisting of tetrakis(2,4-di-t-butyl-phenyl)4,-4'-biphenylylene diphosphonite, tris(2,4-di-t-butylphenyl)-phosphite, trisnonylphenyl phosphite, bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite optionally with 1% tri-isopropyl amine, bis(distearyl)pentaerythritol diphosphite, and bis(distearyl)pentaerythritol diphosphite with one percent (1%) triethanolamine.
Phosphites may also be referred to as organic phosphite esters.
The organic phosphite ester is preferably a pentaerythritol diphosphite which in most instances is characterized by a spiro structure, i.e., ##STR1## where R is an organic radical. Particularly preferred radicals (for R) are alkyl and alkylphenyl. When R is alkyl it should contain 10 to 20 carbon atoms, inclusive, and an especially desirable phosphite is distearyl pentaerythritol diphosphite, when R is alkylphenyl the alkyl substituents should contain 3 to 10 carbon atoms and, preferably, should be tertiary alkyl groups. Tertiarybutyl radicals are especially preferred. The alkylphenyl groups may contain up to three alkyl substituents. The alkyl groups preferably are bulky, i.e., tertiary or secondary alkyl groups. Such alkyl groups include isopropyl, sec-butyl, tertiarybutyl, a-amyl, tertiaryamyl, n-hexyl, 2,2-dimethylbutyl, 2-methyl-2-ethylpropyl, phenyl ethyl and tertiaryoctyl. The two alkyl groups are preferably in the 2, 4, or 6 positions or combinations thereof in the 2,4-positions or 2,6-positions. A particularly preferred species is bis-(2,4-ditertiarybutylphenyl) pentaerythritol diphosphite. Another preferred species is bis-(2,6-ditertiarybutyl-4-methylphenyl) pentaerythritol diphosphite.
The phosphite esters may be made by a variety of methods. Bis alkyl or AlkylAryl Pentaerythritol diphosphites may be prepared via the teachings of U.S. Pat. Nos. 4,305,866, 5,137,950, 4,064,100 or other means described in the literature.
Other phosphite antioxidants which can be employed include trioctylphosphite, trilaurylphosphite, tridecylphosphite, octyl diphenylphosphite, tris(2,4-di-t-butylphenyl) phosphite, tris(nonylphenyl) phosphite, hexa(tridecyl) 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl) butane triphosphite, tetra(C 12-15 alkyl) 4,4'-isopropylidenediphenol diphosphite, tetra(tridecyl)4,4'-butylidenebis(3-methyl-6-t-butylphenol) diphosphite, hydrogenated-4,4'-isopropylidenediphenol polyphosphite, distearyl pentaerythritol diphosphite, phenyl 4,4'-isopropylidenediphenol pentaerythritol diphosphite, bis(2,4-di-t-butylphenyl) pentaerythritol diphosphite, bis(2,6-di-t-butyl-4-methylphenyl) pentaerythritol diphosphite, di(nonylphenyl) pentaerythritol diphosphite and 4,4'-isopropylidenebis (2-t-butylphenol) di(nonylphenyl) phosphite.
Phenolic antioxidants which can be employed in the invention include, but are not limited to, 2,6-di-t-butyl-p-cresol, 2,6-di-phenyl-4-octadecyloxyphenol, stearyl(3,5-di-t-butyl-4-hydroxyphenyl)-propionate, distearyl-3,5-di-t-butyl-4-hydroxybenzylphosphonate, thio-diethylenebis(3,5-di-t-butyl-4-hydroxyphenylpropionate, hexamethylene-bis(3,5-di-t-butyl-4-hydroxyphenylpropionate, 4,4'-thiobis(6-t-butyl-m-cresol), 2-octylthio-4,6-bis(3,5-di-t-butyl-4-hydroxyphenoxy)-s-triazine, 2,2'-methylenebis(4-methyl-6-t-butylphenol), 2,2'-methylene-bis(4-ethyl-6-t-butylphenol), bis(3,3-bis(4-hydroxy-3-t-butylphenyl) butylic acid) glycol ester, 4,4'-butylidenebis (6-t-butyl-m-cresol), 2,2'-ethylidenebis(4,6-di-t-butylphenol), 2,2'-ethylidenebis(4-sec-butyl-6-t-butylphenol), 3,6-dioxaoctylenebis(3-methyl-5-t-butyl-4-hydroxyphenylpropionate), 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)butane, bis(2-t-butyl-4-methyl-6-(2-hydroxy-3-t-butyl-5-methyl benzyl)phenyl) terephthalate, 1,3,5-tris(2,6-dimethyl-3-hydroxy-4-t-butylbenzyl) isocyanurate, 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl) isocyanurate, 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene, 1 , 3 , 5- t r i s ((3 , 5- d i - t - b u t y l - 4-hydroxyphenyl)propionyloxyethyl)isocyanurate, tetrakis(methylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)-propionate)methane.
Metal salts of lactic acids, include metal salts of blends of lactic acid with other organic acids such as fatty acids. Preferred metal salts of lactic acid include calcium lactate and calcium stearoyl lactate. Suitable metals include alkaline earth metals such as calcium, barium, stronium and radium. Suitable metals also include alkali metals such as lithium, sodium, potassium, rubidium, cesium, francium, cadium, lead, zinc, tin, magnesium and antimony. Preferably the metal is bivalent so that the salt may be a co-salt of lactic acid and a fatty acid. Organic acids suitable for use in combination with the lactic acid include stearic acid, lauric acid, palmitic acid, butyric acid and other C 4 to C 2 fatty acids, including both saturated and unsaturated fatty acids, including linoleic and linolenic acids. Suitable fatty acids may be represented by the formula: ##STR2## wherein W is a C 2 -C 20 saturated or unsaturated group. Saturated fatty acids may be represented by the formula: ##STR3## wherein x is selected from 2 to 27.
The preferred salts are bivalent metal co-salts of lactic acid and a fatty acid, preferably a saturated fatty acid. The preferred bivalent metal is calcium. The preferred saturated fatty acid is stearic acid. The preferred metal co-salt is calcium stearoyl lactate. Suitable other co-salts of lactic acid include calcium lauroyl lactate, calcium palmitoyl lactate and calcium butroyl lactate.
The polyolefin resin compositions preferably comprise from 50 to 99.9 weight percent polyolefin resin, more preferably from 90 to 99.5 weight percent thereof, and most preferably from 95 to 99 weight percent thereof based on the total weight of the composition; from 0.001 to 5 weight percent phosphite, more preferably from 0.005 to 3 weight percent thereof, and most preferably from 0.025 to 1 weight percent thereof based on the total weight of the composition; and preferably comprises from 0.01 to 5 weight percent metal salt of lactic acid, more preferably from 0.05 to 3 weight percent thereof, and most preferably from 0.05 to 1 weight percent thereof based on the total weight of the composition.
The composition may also contain or be free of other additives such as waxes, antistatic agents, flame retardants, nucleating agents, plasticizers, hindered amine light stabilizers, and hindered phenolic antioxidants. Optionally the composition contains a hindered phenolic antioxidant at a level of from 0.001 to 5 weight percent, more preferably at a level of from 0.001 to 3 weight percent thereof, and most preferably at a level of from 0.025 to 0.3 weight percent thereof based on the total weight of the composition.
Polyolefin fibers are typically made by melt spinning processes. Melt spinning requires that the polyolefin polymers be stable at temperatures sufficiently above the melting point or softening point of the polyolefin to be extruded in the molten state without substantial degradation. The melt spinning process employs a spinneret, which is a plate containing orifices through which molten polymer is extruded under pressure. Typically the spinneret is made of stainless steel or a nickel alloy. The spinneret is a flat plat, flush with or recessed in its mounting. Spinnerets for molten polymers are usually from 3 mm to 10 mm thick, for melt process pressures of up to 3000 psi. Fibers forming spinneret holes may have exit diameters of from 175 to 750 microns. The number of holes in the spinneret may range from a few to several thousand. A typical process is shown schematically in FIG. 1, wherein the polyolefin composition in particulate form is fed via a hopper 10 to a screw type extruder 12 wherein the composition is melted at elevated temperatures to form a melt stream which is forced at elevated pressures to a metering pump 14 which controls the flow. Optionally there may be a filtration unit (not shown) located at the exit of the extruder 12. The melt stream is then forced through a filter 16, preferably a screen pack filter of filters in series (16 i , 16 ii , 16 iii , 16 iv , 16 v ) with the upstream filters being of a mesh for collecting only large particles and subsequent downstream filters being increasingly fine for collecting smaller particles that pass through the upstream filters, which removes unmelted solids prior to the melt stream reaching the spinneret 18. The filtered use of stream is then forced to the spinneret 18 wherein fibers are formed by passing the melt stream through the die holes of the spinneret. The fibers are then air cooled and converged into the convergence guide 20, then directed to the finish application 22, reels 24, 26, and finally to the spin bobbin 28 wherein the fiber is wound for storage.
As shown in FIG. 2, a film making process may involve feeding polyolefin particulates (pellets or powder) to a hopper 24 of a screw type extruder 26 wherein the particulates are melted and forced to a metering pump 28 (optional) and then forced through a filtering system (preferably a screen pack) 30 which preferably has a series of filters (30 i , 30 ii , 30 iii , 30 iv and 30 v ) which have increasingly fines mesh as the polyolefic melt flows downstream. The filter screens out the unmelted solid by-products before the polyolefin melt stream reaches the die 32 so that the dies orifice 33 will not become clogged by the solid by-products. The melt stream flows from the filter system 30 to the die 32, through the elongated die orifice 33, forming a polyolefin film which then passed partially around and between calendar rolls 34, 36 to storage roll 38 whereupon the film is wound and stored.
As shown in the drawings, before reaching the spinneret, the molten polymer is filtered through a series of sintered or fibrous metal gauzes or a bed of graded fine refractory material, such as sand or alumina, held in place by metal screens. Filtration removes large solid or gel particles that might otherwise block spinneret holes or, if passed through, occupy sufficient cross-sectional area in the filament to affect its processing or tensile properties. Smaller particles, such as delusterants, are not retained by the filter. Filtration also provides shearing, and thus can influence Theological behavior.
EXAMPLES
Example 1 was a polypropylene composition containing 500 parts per million by weight (ppm) bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite (sold under the trademark Ultranox 626 by GE Specialty Chemicals Inc.), 250 ppm of a hindered phenolic compound (sold under the trademark Irganox 3114 by B.F. Goodrich), 500 ppm Calcium Stearoyl Lactate (sold under the trademark Pationic 930 by Patco Polymer Additives Div., American Ingredient, Co.). The polyproylene base resin used in the compositions of the examples was Himont Profax 6301 resin.
Comparative Example 2 has a polypropylene composition as an Example 1, but 500 ppm of Calcium Stearate was used in place of the Calcium Stearoyl Lactate.
Test method--Polypropylene is compounded with additives. Our laboratory compound method 450° F. stock temperature using a 24:1 L/D 1" 2 stage screw with a Maddox mixer between stages. A screen pack composed of 20/100/500/100/20 mesh screens is utilized. Polypropylene is re-extruded using a 3/4" Brabender extruder with a single stage screw 2:1 compression having a Maddox mixer 6" from the screw tip. The output of the extruder is throttled to a 1/4" diameter focus on a screen pack. The screen pack is composed of 20/100/1400×125/100/20 screens. Back pressure is set to 200-300 psi.
The extrusion is performed at 600° F. stock temperature operating the extruder at 10 rpm for 50 min and 50 rpm for 10 minutes out of every hour. Back pressure is set at 200-300 psi. The extrusion is performed until significant pressure rise occurs or if none is observed for 13-16 hrs.
TABLE 1______________________________________Examples Ex 1 CEx 2______________________________________Back Pressure Increase, 0(13 hrs) + 500(8 hrs)psi______________________________________
Note that the examples of the present invention exhibited no back pressure increase after 13 hours of operation whereas the comparative example exhibited a +500 psi increase in back pressure after only 8 hours.
Typical filter mesh sizes are from 20 mesh to 1000 mesh, for example, 20 mesh, 100 mesh and 500 mesh. The higher the mesh number the finer the filtration. The process of the present invention preferably employs a filter fineness of at least 20 mesh, more preferably at least 100 mesh, more preferably at least 500 mesh and most preferably in series of 20 mesh, 100 mesh and 500 mesh so that the upstream filters filter out the largest particles and the downstream filters filter out the fine particles.
Example 3 was a polypropylene composition containing 800 ppm bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, 500 ppm calcium stearoyl lactate, and 250 ppm tris(3,5-di-t-butyl-4-hydroxy benzyl) isocyanurate, and exhibited no screen pack plugging pressure rise during extended use.
Comparative Example 4 was a composition having the formation of Example 3 except the calcium stearoyl lactate was replaced with calcium stearate, and exhibited a substantial rise in pressure during melt extrusion due to screen packplugging.
Example 5 was a polypropylene composition containing 600 ppm bis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, 500 ppm calcium stearoyl lactate. The composition exhibited no screen pack plugging pressure rise during 13 hours of operation.
Comparative Example 6 is a polypropylene composition as in example 5 that the calcium stearoyl lactate was replaced with calcium stearate, and the composition exhibited a 200 psi pressure rise in 7 hours of operation.
|
Melt extrusion processes involving phosphite stabilized polyolefin compositions subject to solid by-product formation during melt extrusion are improved by the addition of a metal salt of a lactic acid to the composition. The processes involving the improved compositions exhibit reduced levels of screen pack plugging during fiber and film extrusion processes than that achieved with fatty acid salts, such as calcium stearate.
| 3
|
FIELD OF THE INVENTION
[0001] This invention relates to a new method for determining oxygen demand of water using photoelectrochemical cells. In particular, the invention relates to an improved direct photoelectrochemical method of determining chemical oxygen demand of water samples using a titanium dioxide nanoparticulate semiconductive electrode. It is particularly adapted for use in an online continuous measurement environment.
BACKGROUND TO THE INVENTION
[0002] Nearly all domestic and industrial wastewater effluents contain organic compounds, which can cause detrimental oxygen depletion (or demand) in waterways into which the effluents are released. This demand is due largely to the oxidative biodegradation of organic compounds by naturally occurring microorganisms. These microorganisms utilize the organic material as a food source. In this process, organic carbon is oxidised to carbon dioxide, while oxygen is consumed and reduced to water.
[0003] An oxygen demand assay based on photoelectrochemical degradation principles has been previously disclosed in patent specification WO2004088305 where the measurement was based on both exhaustive and non exhaustive degradation principles.
[0004] It is an object of the present invention to develop an analyzer based on non-exhaustive degradation principles. It is another object of this invention to develop a online COD analyzer.
BRIEF DESCRIPTION OF THE INVENTION
[0005] To this end the present invention provides a method of determining chemical oxygen demand (COD) of a water sample, comprising the steps of
a) applying a constant potential bias to a photoelectrochemical cell, having a photoactive working electrode and a counter electrode, and containing a supporting electrolyte solution; b) illuminating the working electrode with a light source and recording the background photocurrent produced at the working electrode from the supporting electrolyte solution; c) adding a water sample, to be analyzed, to the photoelectrochemical cell; d) illuminating the working electrode with a light source and recording the hydro dynamic photocurrent produced under continuous flow of the water to be analyzed; e) determining the chemical oxygen demand of the water sample using the formula
[0000]
[
COD
]
=
γ
δ
FAD
×
8000
i
peak
(
mg
/
L
of
O
2
)
or
[
COD
]
=
δ
FAD
×
8000
i
sp
(
mg
/
L
of
O
2
)
[0011] where γ is the dispersion coefficient, δ is the concentration diffusion layer thickness, D is the diffusion coefficient, A is the electrode area, F is the Faraday constant, i peak is the photocurrent peak height and i sp is the saturated photocurrent.
[0012] The applied potential is preferably from −0.4 to +O.8V more preferably about +0.3V.
[0013] The method is applicable to water samples in the pH range of 2 to 10.
[0014] Increasing the injection volume increases sensitivity but the linear response is narrower at higher volumes. An injection volume of 13 μL is preferred.
[0015] A slow flow rate is preferred in order to achieve indiscriminate oxidation of organic compounds. However too low a flow rate may lead to lower sensitivity. A preferred flow rate is 0.3 mL/min.
[0016] In another aspect the present invention provides a second method of measuring COD for online monitoring comprising the steps of
a) applying a constant potential bias to a photoelectrochemical cell, having a photoactive working electrode and a counter electrode, and containing a supporting electrolyte solution; b) illuminating the working electrode with a light source and recording the background photocurrent produced at the working electrode from the supporting electrolyte solution; c) adding a water sample, to be analysed, into the photoelectrochemical cell; d) illuminating the working electrode with a light source and recording the hydro dynamic photocurrent produced under continuous flow of the water to be analysed; e) determining the Chemical Oxygen Demand of the water sample using the formula
[0000]
COD
(
mg
/
L
of
O
2
)
=
Q
net
4
α
FV
×
32000
=
k
Q
net
Where
Q
net
=
α
FV
∑
i
=
1
m
n
i
C
i
α
=
Q
net
Q
theoretical
Q net is the amount of electrons captured during the continuous flow detection,
Q theoretical refers to the theoretical charge required for mineralization of the injected sample
n i, is the oxidation number namely the number of electrons transferred for an individual organic compound during the photoelectrocatalytic degradation,
C i is the molar concentration of individual organic compound,
F is the Faraday constant,
V is the sample volume,
K is the slope, which can be obtained by calibration curve method or standard addition calibration method.
[0022] These methods are useful in online analysis.
[0023] In addition to the counter electrode it is preferred to also use a reference electrode.
[0024] In another aspect this invention provides an online analyser for analyzing water quality on a continuous basis which includes
a) an electrochemical cell containing a photoactive working electrode and a counter electrode, b) a supporting electrolyte solution chamber; c) a light source to illuminate the working electrode d) continuous flow injection means to provide a sample solution to the cell e) control means to
i) actuate the light source and record the background photocurrent produced at the working electrode from the supporting electrolyte solution; ii) control the flow rate of the water sample, to be analysed, to the photoelectrochemical cell; iii) actuate the light source and record the hydro dynamic photocurrent produced under continuous flow of the water to be analysed; iv) determine the chemical oxygen demand of the water sample using any of the formula given above.
DESCRIPTION OF THE DRAWINGS
[0034] Two embodiments of the invention are Illustrated in the drawings.
[0035] FIG. 1 is a schematic illustration of the detection cell used;
[0036] FIG. 2 shows a set of typical photocurrent-time profiles obtained in the presence of organic compounds under continuous flow conditions;
[0037] FIG. 3 illustrates the effect of potential on the peak response of 100 μM glucose;
[0038] FIG. 4 illustrates the effect of injection volume on the photoelectrochemical detection;
[0039] FIG. 5 illustrates the effect of flow rate on the photoelectrochemical detection;
[0040] FIG. 6 illustrates the effect of pH on the photoelectrochemical detection of 100 μM glucose;
[0041] FIG. 7 illustrates the effect of (a) The quantitative relationship between the peak height and concentration (μM) of organic compounds. (b) The quantitative relationship between the peak height and theoretical COD. (c) The correlation between the PECOD and theoretical COD for the synthetic COD test samples using glucose as COD standard;
[0042] FIG. 8 illustrates the photoelectrochemical detection of COD value using glucose as a standard;
[0043] FIG. 9 illustrates the Pearson correlation between the photoelectrochemical COD and standard dichromate COD for real sample measurements;
[0044] FIG. 10 illustrates a typical photocurrent response in continuous flow analysis;
[0045] FIG. 11 illustrates the effect of flow rate on (a) the photoelectrochemical charge and (b) the oxidation percentage;
[0046] FIG. 12 illustrates the effect of pH on the photoelectrochemical detection of 100 μM glucose;
[0047] FIG. 13 illustrates the photoelectrochemical determination of COD value of the synthetic samples: (a) Q net versus C (μM) relationship and (b) the correlation between the PeCOD and theoretical COD;
[0048] FIG. 14 shows the continuous flow-based photoelectrochemical determination of COD of a real sample using the standard addition method.
DETAILED DESCRIPTION OF THE INVENTION
Method 1
Materials and Sample Preparation:
[0049] The Indium Tin Oxide (ITO) conducting glass slides (8 Ω/square) were supplied by Delta Technologies Limited. Titanium butoxide (97%, Aldrich), sucrose, glucose, glutamic acid, and sodium perchlorate were purchased from Aldrich without further treatment prior to use. All other chemicals were of analytical grade and purchased from Aldrich unless otherwise stated. High purity deionised water (Millipore Corp., 18 Ωcm) was used for solution preparation and the dilution of real wastewater samples.
[0050] The GGA synthetic samples used for this study were prepared according to the reported method. All real samples used for this study were collected from bakeries, sugar plants and breweries, based in Queensland, Australia. All samples were preserved according to the guidelines of the standard method. When necessary, the samples were diluted to a suitable concentration prior to the analysis. After dilution, the same sample was subject to the analysis by both the standard dichromate COD method and the flow photoelectrochemical COD detector. A certain amount of solid NaClO 4 equivalent to 2M was added to the sample.
[0051] Preparation of TiO 2 electrodesis the same as previously described in patent specification WO2004088305.
Apparatus and Methods:
[0052] All photoelectrochemical experiments were performed at 23° C. in a thin-layer photoelectrochemical cell with a window for illumination (see FIG. 1 ). It consists of a three-electrode system with a TiO 2 coated working electrode. The flow path and the photoelectrochemical reaction zone were confined by a shaped spacer. The thickness of the spacer is 0.2 mm and the diameter of the window is 10 mm. A saturated Ag/AgCl electrode and a platinum mesh were used as the reference and counter electrodes, respectively. A voltammograph (CV-27, BAS) was used for application of potential bias. Potential and current signals were recorded using a computer coupled to a Maclab 400 interface (AD Instruments). Illumination was carried out using a 150 W xenon arc lamp light source with focusing lenses (HF-200w-95, Beijing Optical Instruments). To avoid the sample solution being heated by infrared light, a UV-band pass filter (UG 5, Avotronics Pty. Limited) was used. Standard COD value (dichromate method) of all the samples was measured with an EPA approved COD analyzer (NOVA 30, Merck).
Analytical Signal Measurement
[0053] FIG. 2 shows a set of typical photocurrent-time profiles obtained in the presence of organic compounds under continuous flow conditions with a constant applied potential of +0.30 V and light intensity of 6.6 mW/cm 2 . The peak-shaped photocurrent profile is the result of concentration dispersion effect of sample flow. The peak in FIG. 2 a shows the unsaturated photocurrent profile with relatively small injection sample volume while the peak in FIG. 2 b shows the saturated photocurrent profile with a large injection sample volume. The baseline (i blank ) for both cases resulted from the photoelectrocatalytic oxidation of water and has been electronically offset to zero. Both peak photocurrent (i peak for unsaturated photocurrent profile) and saturated photocurrent (i sp for saturated photocurrent profile) have resulted from the photoelectrocatalytic oxidation of organic compounds.
[0054] As the baseline is the blank (i blank ) for both cases and offset to zero, both i peak and i sp are net photocurrents, originating from the oxidation of organics and so can be quantitatively related to the diffusion limiting current (i ss ), obtaining from a stationary cell. All organics transported to the TiO 2 electrode surface can be indiscriminately and fully oxidized. Therefore, both i peak and i sp can be used to quantify the COD value of a sample.
Analytical Signal Quantification
[0055] The quantitative relationship between the net photocurrent (i peak or i sp ) obtained under the continuous flow, non-exhaustive photocatalytic oxidation conditions can be developed based on the following postulates: (i) all organic compounds at the electrode surface are stoichiometrically oxidized to their highest oxidation state (fully oxidised); (ii) the overall photocatalytic oxidation rate is controlled by the transport of organics to the electrode surface and the bulk solution concentration-time profile follows the flow-injection dispersion profile; (iii) the applied potential bias is sufficient to remove all photoelectrons generated from the photocatalytic oxidation of organics (100% photoelectron collection efficiency). The concentration dispersion in flow-injection can be described by the dispersion coefficient, γ, which is defined as:
[0000]
γ
=
C
o
C
t
or
C
t
=
1
γ
C
o
(
.1
)
[0000] where, C o and C t are the original concentration and the concentration at a given time, respectively. The dispersion coefficient (γ) is a constant for any given system setup and can be experimentally measured.
[0056] The maximum photocurrent (i peak ) is achieved when C t =C max , which yields:
[0000]
γ
=
C
o
C
max
or
C
max
=
1
γ
C
o
(
0
<
y
<
∞
)
(
.2
)
[0057] The system can attain a saturated status when a large volume sample is injected. Under such conditions, the maximum photocurrent (i sp ) is achieved when C t =C max =C o . That is:
[0000]
γ
=
C
o
C
max
=
1
or
C
max
=
C
o
(
.3
)
[0058] Under the steady-state hydrodynamic mass transfer conditions (Postulate (ii) above), the rate of overall reaction can be expressed as:
[0000]
Rate
=
D
δ
C
t
(
.4
)
[0000] where, D is the diffusion coefficient and δ is the concentration diffusion layer thickness. However, δ is a constant under a given hydrodynamic condition (i.e. flow rate).
[0059] According to the postulates (i) and (iii) above, the number of electrons transferred (n) during photoelectrochemical degradation is constant for a given analyte and the maximum photocurrent (i peak or i sp ) can, therefore, be used to represent the maximum rate of reaction. According to Equation 0.2, the peak photocurrent can be given as:
[0000]
i
peak
=
nFAD
δ
C
max
=
nFAD
δγ
C
o
(
5
)
[0000] where A and F refer to electrode area and Faraday constant respectively.
[0060] According to Equation 2 and 3, the saturated photocurrent can be given as:
[0000]
i
sp
=
nFAD
δ
C
max
=
nFAD
δ
C
o
(
6
)
[0061] Equations 0.5 and 0.6 define the quantitative relationship between the maximum photocurrent and the concentration of analyte. Convert the molar concentration into the equivalent COD concentration (mg/L of O 2 ), we have:
[0000]
i
peak
=
FAD
δγ
×
1
8000
[
COD
]
(
7
a
)
[
COD
]
=
γδ
FAD
×
8000
i
peak
(
mg
/
L
of
O
2
)
(
7
b
)
i
sp
=
FAD
δ
×
1
8000
[
COD
]
(
8
a
)
[
COD
]
=
δ
FAD
×
8000
i
sp
[
mg
/
L
of
O
2
)
(
8
b
)
[0062] Equations 7b and 8b are valid for determination of COD in a sample that contains a single organic compound. The COD of a sample contains more than one organic species can be represented as:
[0000]
[
COD
]
≈
γδ
FA
D
_
×
8000
i
peak
(
mg
/
L
of
O
2
)
(
.9
a
)
[
COD
]
≈
δ
FA
D
_
×
8000
i
sp
(
mg
/
L
of
O
2
)
(
.9
b
)
[0000] where D is the composite diffusion coefficient that depends on the sample composition that is a constant for a given sample.
Optimization of Analytical Signal
Effect of Potential:
[0063] The photocatalytic degradation efficiency at TiO 2 depends on the degree of recombination of photoelectrons and holes. The recombination will lead to the disappearance of holes; therefore, the recombination needs to be suppressed. In this invention the photoelectrons are “trapped” by electrochemical means rather than oxygen. The photoelectrons are subsequently forced to pass into the external circuit and to the auxiliary electrode, where the reduction of oxygen (or other species) takes place. FIG. 3 shows the effect of applied potentials where 100 μM glucose was tested. In the region between −0.4V and 0V, the photocurrent resulting from the oxidation of the glucose increased almost linear with the increase of potential. This is because the collection of electron by the conductive ITO layer in this region is a control step among all the reaction processes, including photocatalytic reactions (the generation of holes and electrons), the oxidation of organic compounds by the holes, the electron transfer from valence band to the conduction band and the reduction reaction at the counter electrode. Under the given experimental conditions, an increase of applied potential (i.e. a positive shift) leads to an increase in the electromotive force, which, in turn, leads to a proportional increase of photocurrent. With the further increase of potential (0-+0.25V), the photocurrent kept increase slowly and but not as quickly as before. At a potential above +0.25V, the charge reached its maximum and there was no significant increasing event up to +0.8V. This demonstrates that the photoelectrons are drawn efficiently at the potential of +0.3V or more positive and that the harvesting of photoelectrons is no longer a controlling step in the photoelectrochemical reaction. At this potential the mass transport of organic compounds to TiO 2 is a control step, which leads to a linear relationship between photocurrent and organic compound concentration. Therefore +0.3V was subsequently used as the detection potential for the rest optimization of experimental conditions and determination of COD in synthetic and real samples.
Effect of Injection Volume and Flow Rate:
[0064] The injection volume and flow rate determine the detection limits, the linear range and sample throughput in flow injection analysis. FIG. 4 shows the effect of injection volume on the photoelectrochemical detection of glucose at a flow rate of 0.3 mL/min. Though FIG. 4 clearly indicates that a larger injection volume results in higher sensitivity, such a larger injection volume also suffers from a narrower linear range. Thus, as an example, when the injection volume was 262 μL, the detection limit could be as low as 0.1 ppm COD, while the linear range was only up to 100 μM glucose (19.2 ppm COD). However, when the injection volume was lower, at 13 μL, the detection limit was about 1 ppm COD and the linear range continued up to 100 ppm COD.
[0065] In a real application, a 1 ppm detection limit is likely to be sufficient, while an upper linear range of only 20 ppm COD will normally be impractical. An upper linear range of 100 ppm COD is desirable. Furthermore, a smaller sample volume also has an advantage in terms of higher sample throughout. Note that a 13 μL injection volume has a sample throughout of 60 per hour while a 262 μL injection volume has a throughput as low as 10 per hour. Therefore, in this work, a standard injection volume of 13 μL was established.
[0066] FIG. 5 shows the effect of flow rate of the analytical signal. It was found that a slower flow rate (i.e. 0.3 mL/min) offers a higher sensitivity and wider linear range. The lower flow rate favors a longer contact time, and therefore allows a more complete equilibration and more sensitive response. Also, at a slower flow rate, less oxidation intermediates will be removed before further oxidation. However, while a low flow rate is essential to achieve indiscriminative oxidation of organic compounds, too low a flow rate (e.g., 0.2 mL/min) may lead to lower sensitivity due to dispersion of the analyte in the flow tubing. Thus a flow rate of 0.3 mL/min was set as a standard for further experimentation.
Effect of pH:
[0067] Variation of pH causes change in the band edge potential of the TiO 2 electrode due to the flat band potential and the band edge potential of oxide semiconductors which have a Nernstian dependence on the pH of the solutions. Moreover, speciation of the TiO 2 surface is pH dependent, and so can affect the level of photoelectrochemical oxidation of water and organic matters in the photoelectrochemical system. Levels of pH<2 were not tested, as the pH of real samples are generally at pH>2. Furthermore, there is a possibility that high acidity would damage ITO sublayer of the TiO 2 electrode. pH effects therefore were investigated under experimental conditions that had been previously optimised. The injection of a blank sample (containing only a 2M NaClO 4 solution) with different pH levels (2<pH<10) did not lead to significant variations in peak response, indicating that the change of pH in this range did not affect the photoelectrochemical oxidation of water.
[0068] FIG. 6 shows the effect of pH on the detection of 100 μM glucose (i.e. 19.2 ppm COD). The peak heights shown in FIG. 6 were obtained in the range of 2<pH<10 and were almost identical. These results demonstrate that pH variations do not affect the oxidation reaction rate of glucose significantly across a wide pH range.
[0069] However, larger peak responses were observed for injection of 2M NaClO 4 at pH=11 and pH=12, indicating that the reaction rate of water splitting may be accelerating dramatically at these very high pH levels. The efficiency of the water splitting reaction is known to be significantly enhanced at high alkaline conditions. Nevertheless, as the pH of wastewater is normally in the range 2<pH<10, where the detection responses are independent of pH, the method is widely applicable.
Validation of Analytical Principle
[0070] Validation of the proposed analytical principle (Equations 5 to 8) was firstly carried out using a group of synthetic samples.
[0071] FIG. 7 a shows the plots of i peak against the molar concentrations of organic compounds. Linear relationships between i peak and C o , as predicted by Equation 5, were obtained for all compounds investigated. Different slopes of i peak versus C o curves for different organics are observed. The slopes decrease in the order of sucrose, GGA, glucose and glutamic acid, following the same order as the number of electrons required to fully oxidize each of the organics (i.e. sucrose (N=48), GGA (N=42), glucose (N=24) and glutamic acid (N=18)). More importantly, the slope ratio between any given two of the organic compounds investigated equals their electron transferred numbers (N 1 /N 2 ), further validating Equation 5. This observation also confirms that all organic compounds at the electrode surface have been indiscriminately mineralised, demonstrating that postulate (i) is valid under the chosen experimental conditions.
[0072] The data of FIG. 7 a also validate postulates (ii) and (iii). Equation 6 can be validated in a similar manner as the characteristics of the i sp versus C o curves are the same as those of i peak versus C o curves shown in FIG. 7 a.
[0073] FIG. 7 b presents plots of i peak against the theoretical COD value of the samples. A linear relationship with the same slope for all organic compounds is obtained, thus validating Equation 7a.
[0074] Equation 8a can be validated in a similar manner as the characteristics of the i sp versus COD curve are the same as those of the i peak versus COD curve shown in FIG. 7 b.
[0075] FIG. 7 c presents a plot of the measured COD (PeCOD) against the theoretical COD value of the samples. The line of best fit with a slope of 1.0268 and R 2 of 0.9984 is obtained. This near unity curve slope demonstrates the applicability of Equation 7b for COD determination. In fact, the data also validate Equation 9a as the GGA sample consists of more than one organic compound. Equations 8b and 9b can be validated in a similar manner as the characteristics of PeCOD versus Theoretical COD curve are the same as those of the i peak versus COD curve shown in FIG. 7 c.
Real Sample Analysis
[0076] FIG. 8 shows a set of typical photocurrent responses. The calibration curve (the insert within FIG. 8 ) was then used for real sample COD calculations, in accordance with Equation 9.
[0077] COD values so obtained were subsequently plotted against the COD value determined by standard dichromate COD method, as shown in FIG. 9 . The Pearson Correlation coefficient between the values obtained from the flow injection photoelectrochemical COD method and the standard COD method indicate a highly significant correlation (r=0.996, P=0.000, n=17) between the two methods. This almost unity slope (1.06) indicates that both methods accurately measure the same COD value. At a 95% confidence interval, the slope is between 0.9973 and 1.155. Considering the analytical errors associated with both the flow injection photoelectrochemical COD and the standard method measurements will contribute to scatter on both axes, the strong correlation and slope obtained offers compelling support for the suitability of the flow injection photoelectrochemical COD method for measuring Chemical oxygen demand.
[0078] It is notable that a practical detection limit of 0.5 ppm COD with a linear range up to 60 ppm COD is achievable under the experimental conditions employed. The detection limit can be further extended by increasing the sample injection volume, while the linear range can be increased by using smaller injection volumes. Response reproducibility was also tested. Repetitive injections (n=21) of 100 μM glucose gave an RSD % of 0.8%.
Method 2
[0079] In this second method, the materials and sample preparation, electrode preparation and apparatus are the same as for method 1.
Detection Principle
[0080] Under suitable conditions, the photocurrent originating from the photocatalytic oxidation of organics can be obtained and subsequently used as the analytical signal for determination of COD, as it represents the extent of oxidation. The thin-layer photoelectrochemical detector (see FIG. 1 ) used in this work is a consumption type detector as the organic compounds in the sample are photoelectrochemically oxidized at the TiO 2 working electrode.
[0081] In the applicant's previous patent filing, (WO 2004/088305), exhaustive degradation was achieved by employing a stop-flow operation mode. Under those conditions, the number of electrons captured (Q exhaustive ) is equal to the theoretical charge (Q theoretical ) of mineralization of an organic compound in the injected sample and can be expressed by Faraday's Law:
[0000]
Q
exhaustive
=
Q
theoretical
=
FV
∑
i
=
1
m
n
i
C
i
(
10
)
[0000] where n i, , the oxidation number, refers to the number of electrons transferred for an individual organic compound during the photoelectrocatalytic degradation, C i is the molar concentration of individual organic compound; F and V represent Faraday constant and sample volume, respectively.
[0082] However, in the continuous flow mode of this current invention, and under controlled conditions, only a portion of the organic compounds in any sample will have been degraded. This degraded portion can be represented by a, the oxidation percentage, which is defined as:
[0000]
α
=
Q
net
Q
theoretical
(
11
)
[0083] Where Q net is the number of electrons captured during the continuous flow detection, while Q theoretical refers to the theoretical charge required for complete mineralization of the injected sample.
[0084] If all organic compounds can be oxidized indiscriminately, it can be assumed that the oxidation percentage is a constant, which is similar to the situation that occurs in a consumption-type detection in continuous flow mode. The amount of electrons captured by the detector can be written as:
[0000]
Q
net
=
α
FV
∑
i
=
1
m
n
i
C
i
(
12
)
[0085] Since each oxygen molecule equals to 4 transferred electrons:
[0000] O 2 +4H + +4 e − →2H 2 O (13)
[0000] and according to COD definition, the Q net can be readily converted into equivalent COD value [ref].
[0000]
COD
(
mg
/
L
of
O
2
)
=
Q
net
4
α
FV
×
32000
=
kQ
net
(
14
)
[0086] Equation 14 can be used to directly quantify the COD value of a sample when Q net is obtained, since k, the slope, can be obtained by the calibration curve method or the standard addition calibration method.
[0087] FIG. 10 shows a typical photocurrent-time profile obtained during the degradation of organic compounds under continuous flow conditions. It can be used to illustrate how Q net is obtained. The flat baseline (blank) photocurrent (i baseline ) observed from the carrier solution originates from water oxidation, while the peak response observed from the sample injection is the total current of two different components, one that originates from photoelectrocatalytic oxidation of organics (i net ), while the other is from water oxidation, (i.e., which is the same as the blank photocurrent). The net charge, Q net , originating from oxidation of organic compounds can be obtained by integration of the peak area between the solid and dashed line, i.e., the shaded area as indicated in FIG. 10 .
Thin-Layer Photoelectrochemical Flow Detector
[0088] A thin-layer photoelectrochemical detector was specifically designed to suit on-line photoelectrochemical determination of COD under continuous flow conditions.
[0089] The thin-layer configuration is a key feature of the design. Such a configuration is essential to achieve a large (electrode area)/(solution volume) ratio that ensures rapid photodegradation of an injected sample. It also provides reliable and reproducible hydrodynamic conditions, which are crucial for accuracy, reproducibility and reliability. In addition, a thin liquid layer maximises light utilisation efficiency because the aqueous media also absorbs UV radiation. A suitable TiO 2 nanoparticulate electrode was chosen that was mechanically stable, suited to a wide spectrum of organic compounds, and capable of indiscriminate organic compound photooxidation.
[0090] The light source is another important component, since the effective light intensity is an important parameter affecting degradation rate. Thus a modified Xenon light source was employed with an output beam regulated in terms of size and intensity of the beam by a group of quartz lenses. A UV-band pass filter was used to reduce infrared radiation reaching the detector, and so prevent solution heating.
Optimization of Analytical System
[0091] A potential bias of +0.3V vs Ag/AgCl was selected to ensure that maximum electron efficiency is achieved.
[0092] Effect of flow rate and concentration: Based on the proposed detection principle, the magnitude of analytical signal (Q net ) is dependent on the total amount of organics oxidised at the electrode. Therefore for a given injection volume, the total amount of organics oxidised at the electrode is governed by the flow rate (determining the contact time) and concentration (determining mass transport to the electrode).
[0093] According to Equation 12, Q net should be directly proportional to the molar concentration. Thus FIG. 11 shows the relationship between Q net and concentration obtained from the photodegradation of glucose at various flow rates. A linear relationship within the medium concentration range was observed for all flow rates investigated. This indicates that the oxidation percentage is independent of concentration under these conditions and so rationalises the assumption made for Equation 14. It was noted that the slope of the curve increased as the flow rate decreased. That is, an increase in flow rate results in a decrease in the sensitivity. This is because a low flow rate allows longer sample-electrode contact time for the sample to react, therefore, for a given concentration, more charge resulting from photocatalytic oxidation can be collected. The basis of Equation 14 is further confirmed by the direct relationship between oxidation percentage and concentration (as shown in FIG. 11 b ). At a low flow rate (0.3 mL/min), the oxidation percentage is constant throughout the concentration range investigated. However, at higher flow rates, a constant oxidation percentage could only be maintained at higher concentrations (>40 μM glucose), and fluctuations in the oxidation percentage are noted at lower concentrations (<40 μM glucose). These results confirm that an increase in flow rate leads to a decrease in the overall oxidation rate and, consequently, in the sensitivity of detection. Considering the overall effect of the flow rate, 0.3 mL/min set as a standard for further work.
Effect of Injection Volume
[0094] The injection volume is one operational parameter that can strongly influence the detection sensitivity and linear range as it determines the sample contact time at the electrode under a constant flow rate.
[0095] Table 1 shows the effect of injection volume on the detection limits and linear range. It was found that when injection volume was increased from 13 μL to 262 μL, the detection limit improved from 1 ppm down to 0.1 ppm. However, despite this improvement in detection limit (sensitivity), too high an injection volume can significantly reduce the linear range, as large amounts of analytes can surpass the capacity of the photoelectrochemical detector. When this occurs, the oxidation percentage (α) will change with concentration and Equation 14 will become invalid. Therefore, for the work reported here, a small injection volume of 13 μL was selected to assure the validity of Equation 14. This injection volume was chosen to permit the widest linear range (1-100 ppm COD), at satisfactory sensitivity and detection limits. Additionally, such a small injection volume allows a short assay time.
[0000]
TABLE 1
Effect of injection volume on detection limit and linear range
Injection volume
Detection limit
Linear range
(μL)
(ppm COD)
(ppm COD)
13
1
1-100
36
0.6
1-70
50
0.5
1-50
110
0.2
0.5-40
262
0.1
0.5-20
Note:
Flow rate = 0.3 mL/min.
Effect of pH
[0096] FIG. 12 shows the effect of pH on the resultant analytical signal (Q net ), where all experiments were carried out under identical conditions except pH change. The conditions for pH<2 were not investigated here because damage of the ITO conductive layer can occur under such acidic conditions. For a given concentration, no significant changes in Q net were observed when the solution pH was varied from 2 to 10. However, a sharp increase in Q net was observed when the solution pH was greater than 10. A question arising from this observation is whether the sharp increase in Q net is due to increasing oxidation efficiency towards the organics or to other factors. Therefore, to clarify this, the effect of solution pH on the blank current (baseline) was investigated. Blank solutions containing 2M NaClO 4 with various pHs were injected. These experiments revealed that within pH range of 2 to 10, a change in solution pH had no measurable effect on the blank current. However, a sharp increase in the blank current was observed when at a solution pH greater than 10. Interestingly, the magnitude of the increase matched the value increase observed from the oxidation of glucose. This implies that the increase in Q net at high pH (in the case of glucose) was due to the increase in the blank current rather than due to any increase in oxidation efficiency towards glucose. Thus, the increase in the blank current (baseline) is due to the increase in water oxidation efficiency at high OH − concentration. This suggests that sample pH should be adjusted to be in the suitable range (2<pH<10) before analysis.
Synthetic Sample Analysis
[0097] The applicability of the proposed detection principle was examined using synthetic samples prepared with pure organic compounds with known theoretical COD value. FIG. 13 a ) shows the plot of Q net against synthetic sample concentration in μM. Different slopes for different synthetic sample were observed. It revealed that the slopes decreased in the order of sucrose>GGA>glucose>glutamic acid. This is because the mineralisation of different organic compounds requires different numbers of electrons. For a given molar concentration, an organic compound having a larger n will generate more charge, hence a larger slope as shown in FIG. 13 a ). The numbers of electrons required for mineralisation of one mole of the above samples are: sucrose (n=48 moles)>GGA (n=42 moles)>glucose (n=24 moles)>glutamic acid (n=18 moles), which is in the same order as that of the slopes in the figures.
[0098] According to Equation 14, the measured net charge should be directly proportional to the COD value of the sample. The μM concentration shown in FIG. 13 a can be converted into the equivalent COD value according to the oxidation number (n). Plotting Q net against the theoretical COD value of the synthetic samples gives a straight line, y=19.605x+1.5887, R 2 =0.999. This demonstrates that the conversion of molar concentration of different samples into equivalent COD values is an effective normalisation process. For a given sample with known concentration, the theoretical charge (Q theoretical ) required for mineralisation can be readily calculated using Equation 10. Therefore, the oxidation percentage (α) can be calculated once the net charge (Q net ) of the sample is obtained using Equation 11. In FIG. 13 b , glucose was used as a calibration standard to obtain a slope k. The COD values of the synthetic samples can then be calculated according to Equation 14 using the slope k. FIG. 13 b shows the photoelectrochemical COD (PeCOD) values plotted against theoretical COD values. The trendline of best fit has a slope of 1.0145 with a R 2 of 0.9895, which demonstrates the applicability of Equation 14. A detection limit of 0.1 ppm COD and a linear range up to 100 ppm COD can be achieved depending on the injection volume and flow rate. The detection limit can be further improved by increasing the sample injection volume while the linear range can be extended by a further decrease of injection volume. The reproducibility is represented by RSD % of 0.8% that obtained from 12 repeated injections of 100 μM glucose. No significant change for Q net was obtained from injections of 100 μM glucose over a period of 60 days. The electrode fouling caused by organic contamination and bacteria growth was not observed during the storage due to the well-known merits of self-cleaning ability of TiO 2 (24).
Real Sample Analysis
[0099] The applicability of the method for real sample analysis was examined. The pH of the real samples tested in this work was within the range of 6-8 (the pH independent region). The standard addition method can be used to determine the COD value in real sample to eliminate possible signal variation caused by the complex sample matrix. FIG. 14 shows the typical photocurrent profile of the continuous flow responses, and the COD value of the real sample determined using standard addition method.
[0100] Each sample was analysed by both the continuous flow photoelectrochemical method and the standard dichromate method. The insert in FIG. 14 shows the correlation between the COD values obtained by both methods. The Pearson Correlation coefficient between the values obtained indicate a highly significant correlation (r=0.991, P=0.000, n=14) between the two methods. The almost identical slope (1.064) indicates that both methods accurately measure the same COD value. At a 95% confidence interval, this slope was between 1.001 and 1.154. Considering the analytical errors associated with measurements performed by both methods and that these errors contribute to scatter on both axes, the strong correlation and almost unity in slope obtained demonstrates the applicability of the continuous flow photoelectrochemical method for determination of chemical oxygen demand.
[0101] From the above it can be seen that this invention provides an improved method and apparatus for use in continuous COD analysis of water samples. Those skilled in the art will realize that this invention may be implemented in embodiments other than those described without departing from the core teachings of the invention.
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A method of determining chemical oxygen demand (COD) of a water sample, which is useful in an on-line configuration comprising the steps of a) applying a constant potential bias to a photoelectrochemical cell, having a photoactive working electrode, optionally a reference electrode and a counter electrode, and containing a supporting electrolyte solution; b) illuminating the working electrode with a light source and recording the background photocurrent produced at the working electrode from the supporting electrolyte solution; c) adding a water sample, to be analysed, to the photoelectrochemical cell; d) illuminating the working electrode with a light source and recording the hydro dynamic photocurrent produced under continuous flow of the water to be analysed; e) determining the chemical oxygen demand of the water sample using a number of different formulae. The applied potential is preferably from −0.4 to +O.8V more preferably about +0.3V. The method is applicable to water samples in the pH range of 2 to 10. An injection volume of 13 μL is preferred. A preferred flow rate is 0.3 mL/min.
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FIELD OF THE INVENTION
The invention relates to a method of heating a jacketed working surface of a rotating roller, where heat is supplied to a fluid heat transfer medium immediately below the jacketed working surface via a heat exchanger through which a heating medium is made to flow.
BACKGROUND OF THE INVENTION
The invention also relates to a rotary roller having a jacketed working surface and a heat exchanger in a fluid heat transfer medium in an annular space immediately below the jacketed working surface, which heat exchanger comprises a system of ducts connected to a heating medium circulator.
The invention has been especially developed for use in the heat treatment of woven textiles, in particular felt and machine wires for use in the manufacture of paper. When treating felt for paper-making machines with the aid of oil-heated rollers, accurate control of the temperatures over the surface of the rollers is required.
GB-PS 1,513,732 makes known the heat treatment of woven textiles and other materials by using a rotating roller. Immediately below the jacketed working surface of the roller, provision is made for the presence of a fluid heat transfer medium which, with the aid of a heat exchanger inside the roller, can be heated as required. The heat exchanger is in the form of a system of ducts through which flows a heating medium, e.g., oil. As a heat transfer medium, a liquid is used which evaporates in a closed space that is heated via the heat exchanger, and where condensation occurs at cold points of the jacketed working surface. In this known roller, two different media are used as the heating medium and the heat transfer medium respectively.
SUMMARY OF THE INVENTION
According to the present invention, it is proposed to carry out the method mentioned by way of introduction in such a way that the heating medium is used as the fluid heat transfer medium.
The advantage achieved by means of the invention is that only one fluid medium is employed, viz., oil, and that in the space immediately below the jacketed working surface a buffer layer of oil is established which communicates with the oil that flows as a heating medium through the heat exchanger.
While a major portion of the heating medium from the heat exchanger communicates with the buffer layer, a smaller portion of the heating medium can to advantage be made to flow in the form of discrete jets, preferably having a single direction, into the heat transfer medium constituted by the heating medium. Thus, an enhanced heat distribution in the buffer layer is obtained. The discrete jets may to advantage be directed in such a way that they will set the buffer layer of oil in slow rotation.
The heating medium may to advantage be made to flow in opposite directions in adjacent ducts in the heat exchanger.
According to the invention, a rotary roller is also proposed having a jacketed working surface and a heat exchanger in a fluid heat transfer medium in an annular space immediately below the jacketed working surface, which heat exchanger comprises a system of ducts connected to a heating medium circulator. The rotary roller according to the invention is characterised in that the ducts in the system, at a respective end at a distance from the connection to the heating medium circulator, have open flow connection with the annular space.
In a rotary roller of this kind, one may thus to advantage work with oil as the only flowing medium, and in the annular space a buffer layer of oil will be built up which will be instrumental in evening out the temperature differences on the roller surface.
The rotary roller may to advantage be made with ducts evenly distributed around the axis thereof. This gives rise to an even heat exchange.
This even heat exchange can be further improved by allowing the ducts to be flow connected to feed pipes and return pipes in the axis of the roller, the connections being positioned so that the direction of flow in one duct will be opposite to that in the adjacent duct.
The ducts preferably run axially in the roller, but they may also run in, e.g., a helical pattern.
It would be of particular advantage if the ducts could have flow connection openings facing the annulus, distributed axially in the roller. The heating medium will be able to pass through these flow connection areas into the annulus space in the form of discrete jets which will activate the buffer layer in the annulus in such a way that small flowing movements occur in the buffer layer in the annulus.
It would be of particular advantage if the flow connection openings could be directed in substantially the same direction, for initiating and maintaining a helical flow in the buffer layer in the annulus. According to the invention, the ducts may to advantage be made in that sheet profiles, trough-shaped in cross-section, are placed bottom up on an inner roller jacket.
Here, separate sheet profiles may be used or one sheet bent into a corrugated form, which is placed on the inner roller jacket.
A second advantageous practical embodiment is one in which the ducts are formed by strip-shaped elements which lie on an inner roller jacket and are covered by an enveloping intermediate roller jacket.
The sheet profile, the strip elements and the intermediate jacket respectively may to advantage be welded in place in a simple manner on the inner jacket by means of spot welding, as a certain amount of leakage between the ducts would not represent a disadvantage.
BRIEF DESCRIPTION OF THE INVENTION
The invention will now be explained in more detail with reference to the drawings, where:
FIG. 1 is a perspective view of a roller according to the invention, partially cut-away;
FIG. 2 is a fragmentary section through the jacket area of the roller illustrated in FIG. 1;
FIG. 3 is a perspective section of the duct system in the embodiment in FIGS. 1 and 2;
FIG. 4 is a fragmentary section through the jacket area of an alternative roller embodiment;
FIG. 5 is a partially cut-away perspective view of another possible embodiment of the roller;
FIG. 6 is a schematic longitudinal section through the roller embodiment in FIG. 1;
FIG. 7 is a schematic longitudinal section through a possible embodiment of the roller; and
FIG. 8 is a second schematic longitudinal section through a possible embodiment of the roller.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of a rotary roller according to the invention, illustrated in FIG. 1 (see also FIG. 6), is constructed having an inner jacket 1, concentrically surrounded by an outer jacket 2, which forms the jacketed working surface of the roller, and two end shields 3 and 4. The roller has a journal 5 at one end and a journal 6 at the other end.
The journal 6 has two concentric bores, indicated by means of dotted lines and arrows, for the supply of a heating medium, in particular oil, to the interior of the roller. These bores 7 and 8 form a part of a circulator, which also comprises an intake chamber 9 and a discharge or return chamber 10 in the end of the roller, provided in that in the inner jacket 1 two wall plates 11, 12 are installed. The intake chamber 9 communicates with the inlet 7 through radial holes 13, whilst the return chamber 10 communicates with the discharge or return pipe 8 through radial holes 14.
A bent sheet 15 (see also FIGS. 2 and 3) is placed on the inner jacket 1. The sheet is bent in such a way as to form ducts 16 with the inner jacket 1. The sheet 15 may to advantage be spot welded 17 to the inner jacket 1.
Instead of a sheet, one may, of course, construct the ducts with the aid of trough-shaped or hat-shaped sheet profiles which are placed on the inner jacket 1. The sheets or sheet profiles are positioned in such a way on the inner jacket 1 that, in the exemplary embodiment in FIGS. 1 and 6, they extend from the end shield 4 up to but at a distance from the second end shield 3, in such a way that a collecting chamber 18 is formed with which all the ducts 16 communicate freely. The collecting chamber 18 also has free flow connection with the annulus 19 between the inner and outer jackets 1, 2, i.e., with the part of the annulus which lies outside the heat exchanger which the ducts 16 constitute. Every second duct 16 has flow connection 20 with the intake chamber 9. The intervening ducts 16 have flow connection 21 with the return chamber 10.
During operation, the roller is supplied with oil as indicated by the arrow 7, through the radial openings 13 and into the intake chamber 9. From there, the oil passes through the individual openings 20 into every second duct 16 and then out into the collecting chamber 18, where there is free flow connection with the surrounding space 19. There, a buffer layer of oil will thus be formed. The return oil passes through the ducts 16 which by means of the respective openings 21 have flow connection with the return chamber 10, from where the oil passes through the radial holes 14 and out as indicated by the arrow 8. Thus, the oil in the heat exchanger flows in opposite directions in adjacent ducts 16.
The purpose of the buffer layer which is formed in the space 19 is to even out the differences in temperature on the roller surface. To enhance the distribution of heat in the buffer layer of oil, the embodiment in FIGS. 1 and 6 is based on a certain amount of the oil from the ducts 16, especially from the inlet ducts, for example 10% of the total amount of oil in circulation, being jetted into the buffer layer in the annulus 19 through openings 22 distributed on the different ducts 16, preferably all pointing in the same direction, thus setting the buffer layer of oil in the annulus 19 in slow rotation. The amount of oil that is fed into the buffer layer will slowly flow out towards the collecting chamber or equalising chamber 18 simultaneously with the slow rotation flow, and thence on into the return ducts and to the return chamber 10.
The outer jacket 2 is, in principle, made in the form of a separate jacket that lies freely spaced from the duct profiles 15. If necessary, the outer jacket can in practice, of course, be permitted to rest against the inner jacket 1, but, in principle, this is to be an independent jacket freely spaced from the underlying oil ducts 16. The new roller has a constructive structure that is such that it makes possible a considerable reduction in the welding work that is necessary in comparison with conventional rollers.
The roller embodiment illustrated in the section in FIG. 4 is constructed in the same way as the roller in FIGS. 1 and 6, with the exception that the actual heat exchanger is constructed in a different way, in that in this case, instead of sheet profiles, longitudinal strips 23 have been placed on the inner jacket 1'. These strips 23 are enveloped by a thin sheet jacket or intermediate jacket 24, in such a way that ducts 16' are thus produced, corresponding to the system of ducts 16 which have been shown and described above. An annulus 19' remains outside the intermediate jacket 24 to accommodate the oil buffer layer. The strips 23 and the intermediate jacket 24 are affixed advantageously by means of spot welds (not shown).
A variant of the embodiment in FIG. 1 is shown in FIG. 5. The difference resides in that the sheet profiles 15" are placed in a helical pattern on the inner jacket 1", so that ducts 16" are correspondingly formed having a helical course. In other respects the embodiment is as in FIG. 1.
In the embodiment in FIGS. 1 and 6, the equalising chamber 8 is positioned at one end of the roller. In the embodiment in FIG. 7, this equalising chamber 18"' is positioned centrally across the length of the roller, and provision is made for inlet and discharge at both ends of the roller, corresponding to the inlet/discharge assembly shown in FIG. 6. The oil will thus flow from the two intake chambers 9"' and through the ducts into the equalising chamber 18"', where there is free flow connection for building up the buffer layer against the outer roller jacket 2"'.
Another possible variant is illustrated in FIG. 8 where the intake chamber 9"" and the return chamber 10"" are shown positioned centrally in the roller, with a respective equalising chamber 18"".
The illustrated embodiments are, of course, only intended to be illustrations of possible embodiments and are neither exhaustive nor limiting. The constructive structure of the heat exchanger can be carried out in many ways within the scope of the invention, as long as one simply keeps in mind that what is essential is that a buffer layer is formed against the outer jacket, i.e., the jacketed working surface.
The openings 22, which are only shown in FIGS. 1, 2 and 3, may, of course, be used in all the exemplary embodiments, and they can have many different embodiments. A particularly interesting embodiment is one in which the openings are positioned in such a way that they point in the same direction and that oil will thereby pass from the ducts and into the annulus having a directed effect, such that a slow rotational movement is initiated and maintained, preferably with varying degrees of helical pitch.
The invention provides a method and a rotary roller which result in a good evening out of the temperature differences on the roller surface. A problem is thus solved which in connection with heat treatment phases is to the effect that in the heating phase, before the roller temperature has stabilised, not insignificant temperature differences could occur in shortish periods of time between the different points in the roller path as a result of the difference in temperature between the oil ducts that are built into the rollers. This can, at times, in connection with the use of chemicals with added temperature-sensitive colour indicators, result in bar-patterned markings on the felt or roller contact. The bar pattern remains visible even after the felt has later been treated at an even temperature. Reduced temperature variations on the surface will help to reduce this bar-pattern problem.
The invention is directed towards the heating of a roller. This concept should here be seen also to comprise the cooling of a roller, as an equal technical process.
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To obtain an enhanced evening out of differences in temperature on a roller surface, it is proposed to establish or to make a roller such that a buffer layer of oil is formed against the inside of the roller surface. This buffer layer is heated by means of a heat exchanger in which oil flows. The heat exchanger is made having open flow connection with the buffer layer.
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TECHNICAL FIELD
The present invention generally relates to methods of thermoforming a laminated thermoplastic sheet, wherein the sheet is capable of achieving a class “A” automotive finish. More particularly, the present invention relates to a thermoforming method which consistently achieves a class “A” finish of a laminated thermoplastic sheet.
BACKGROUND OF THE INVENTION
Automobile fascias, body side moldings (BSM), rockers, etc., are typically produced by an injection molding process followed by painting. The last steps of the painting process require that the painted part be baked for about 30 minutes at, for example, 250 degrees F. This production procedure is proven and functions well. However, there are a number of negatives associated with this process, including: a high scrap rate due to paint defects, expensive tooling costs, burdensome provisions for protection against possible mutilation in handling, and poor stone impact performance in sensitive areas of a motor vehicle (ie., under highway driving conditions, stones kicked up by other motor vehicles striking certain prone areas of the painted part).
Presently, however, new technologies are developing with the intention of eliminating the high cost of fabricating injection molding tools, and producing parts through the aforementioned injection molding and painting process. These technologies involve, as can be understood by reference to FIG. 1 , a laminated thermoplastic sheet 10 which is formed in a thermoforming process. The laminated thermoplastic sheet 10 is composed, for example, of a paint film 12 , which may optionally include a paint layer 12 a and a clear coat 12 b , wherein the color, finish and gloss of the class “A” side of the laminated thermoplastic sheet is matched to that of the paint of the motor vehicle to which the laminated thermoplastic sheet is to be used. A removable mask 12 c is provided to protect the paint film 12 is removed when the part 20 is completed. The paint film 12 is bonded onto one side of a thermoformable thermoplastic substrate 18 , via an adhesive layer 16 , wherein the substrate may be, for nonlimiting example, thermoplastic polyurethanes, polyesters, vinyl copolymers, polyvinylchlorides, thermoplastic olefin (TPO), ABS, polyethylene, and blends, copolymers and/or alloys thereof.
Examples of laminated thermoplastic sheets 10 and methods of forming laminated thermoplastic sheets into formed parts 20 are described in U.S. Pat. No. 4,976,896 issued on Dec. 11, 1990 to the assignee hereof, U.S. Pat. No. 4,769,100 issued on Sep. 6, 1988 to the assignee hereof, and U.S. Pat. No. 4,868,030, issued on Sep. 19, 1989 to the assignee hereof; the disclosures of each of said U.S. Pat. Nos. 4,976,896, 4,769,100 and 4,868,030 being hereby herein incorporated by reference. Other U.S. patent references describe additional aspects of laminated thermoplastic sheets and the thermoforming processes therefor, as for example U.S. Pat. Nos. 6,450,793 and 6,709,734 and U.S. Patent Application Publication 2004/0076846.
While the technology for thermoforming laminated thermoplastic sheets has become well established, there yet remains the problem that the thermoforming process adversely affects the gloss of the class “A” finish. For example, the gloss of the class “A” finish may start at a gloss value above 70 but, as a result of thermoforming, the gloss value becomes unacceptably less than 70. Accordingly, in the prior art of thermoforming of laminated thermoplastic sheets, parts have inconsistent finish and gloss, resulting in scrap and/or parts having a finish and/or gloss which does not well match the finish and/or gloss of the paint of conventionally painted surfaces of the motor vehicle.
Accordingly, what is needed in the art of thermoforming laminated thermoplastic sheets, is some methodology associated with the thermoforming process which preserves, reliably under high volume production conditions, the class “A” finish of the laminated thermoplastic sheet which well matches the finish of conventionally painted surfaces of a motor vehicle, and retains a gloss value, after thermoforming, of above 70.
SUMMARY OF THE INVENTION
The present invention is a thermoforming methodology for laminated thermoplastic sheets which preserves, reliably under high volume production conditions, the class “A” finish of the laminated thermoplastic sheet which well matches the finish and gloss of conventionally painted surfaces of a motor vehicle, wherein the sheet retains a gloss value, after thermoforming, of above 70.
The thermoforming process according to the present invention utilizes a thermoforming apparatus including one or more heating stations and a thermoformer. The thermoformer has two mutually separable components: a vacuum box component which includes a mold, and a pressure box component in which chilled, pressurized air is introduced in order to thereby control cooling of the laminated thermoplastic sheet, which controlled cooling results in preservation of the class “A” finish and gloss value above 70.
A laminated thermoplastic sheet, as for example of the type described hereinabove, is loaded, in a conventional manner, onto a frame at a first station of a thermoformer apparatus.
Thereafter, the frame containing the laminated thermoplastic sheet is moved to a heating station, wherein preferably both the class “A” side of the sheet and the opposite class “B” side of the sheet are each heated by respective heater banks. The heater station heats the laminated thermoplastic sheet into a moldably softened state. Optionally, a pre-heat station may be provided.
Next, the laminated thermoplastic sheet is moved into position in the thermoformer, wherein the vacuum box and pressure box components are presently separated from each other, wherein of the laminated thermoplastic sheet is disposed between the vacuum box and pressure box components, and wherein the class “A” side of the sheet faces toward the pressure box component and the class “B” side of the sheet faces toward the mold of the vacuum box component.
Now, the vacuum box and pressure box components are mutually closed together, whereby the perimeter surfaces thereof mutually engage to provide an air-tight seal therebetween.
Once the perimeters of the vacuum box and pressure box components mutually seal, a cooling line in the mold is activated, and a vacuum (by “vacuum” is meant air pressure below atmospheric pressure) is applied to the vacuum box side of the laminated thermoplastic sheet, causing the class “B” side of the sheet to be sucked formingly onto the surface of the mold, and simultaneously compressed air (by “compressed air” is meant air under pressurization above atmospheric pressure) is forced into the pressure box component at the class “A” side of the laminated thermoplastic sheet, causing the sheet to be pressed formingly onto the surface of the mold.
As soon as the laminated thermoplastic sheet has formed onto the surface of the mold, the compressed air is vented as chilled compressed air (by “chilled compressed air” is meant compressed air at a temperature below substantially 70 degrees F.) is continuously flushed into the pressure box. The chilling of the chilled compressed air can be provided, for example, by a refrigeration and/or a throttling process. The chilled compressed air cools the laminated thermoplastic sheet in a rapid and controlled manner which is critical to preservation of finish and gloss of the class “A” side thereof. Alternatively, the chilled compressed air can be used throughout the forming and cooling processes.
Critical to the success of forming a class “A” part is the rate of cooling of the class “A” side of the laminated thermoplastic sheet. The class “A” side temperature needs to be reduced to less than 190 degrees F. within 30 seconds of initial forming of the sheet on the mold, more preferably within 20 seconds, and most preferably within 15 seconds. An infrared temperature sensor is used to indicate the class “A” side temperature of the laminated thermoplastic sheet.
Once the part is formed of the laminated thermoplastic sheet, the vacuum box and pressure box components are again separated, and the formed laminated thermoplastic sheet is removed, in a conventional manner from the mold. Next, the formed thermoplastic sheet is moved to a next station where it is removed, in a conventional manner, from the frame, put onto a cooling fixture, and then moved to a trimming station which trims it so as to provide a completed part.
Accordingly, it is an object of the present invention to eliminate the injection molding fabrication and painting process by providing a laminated thermoplastic thermoformed part having a class “A” finish and having a preserved gloss value above 70.
This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken-away, sectional side view of a prior art thermoformed part, the part being conventionally thermoformed from a conventional laminated thermoplastic sheet.
FIG. 2 is a flow chart of thermoforming steps according to the method of the present invention.
FIGS. 3A through 3G are schematic views depicting a series of sequential steps of the method of FIG. 2 .
FIGS. 4A and 4B are schematic views depicting an alternative embodiment of the thermoformer of FIGS. 3C through 3G .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Drawing, FIGS. 2 through 4B depict various aspects of the thermoforming process 100 according to the present invention. In this regard, FIG. 2 depicts the thermoforming process 100 as a block flow chart 102 , and FIGS. 3A through 4B depict schematic views of various steps of the flow chart of FIG. 2 .
At Block 102 of the block flow chart 100 , a laminated thermoplastic sheet 200 (see FIGS. 3A through 4B ) is provided and loaded, in a conventional manner, onto a frame at a first station of a thermoformer apparatus, which may be, for example, configured for rotational loading, sled loading, or other form of loading.
The laminated thermoplastic sheet 200 may, for example, be of the type described hereinabove. By way merely of preference and not limitation, the thermoplastic carrier sheet of the laminated thermoplastic sheet 200 may have the following specifications: the composition is a thermoplastic olefin (TPO) material, having a stock thickness ranging between 40 and 400 thousandths of an inch, more preferably between 60 and 180 thousandths of an inch, and most preferably between 100 and 160 thousandths of an inch. Further by way merely of preference and not limitation, the paint film of the laminated thermoplastic sheet 200 may have the following specifications: the paint film is laminated to the thermoplastic carrier sheet, and consists of a PVDF/PMMA dispersion with color matched to specific vehicle paint; a mask is incorporated with composition primarily of polyurethane, commonly referred to as a “Version 14” or a “Version 8” available, for example through Soliant, LLC. of Lancaster SC 29720. Other paint films are usable.
At Block 106 , the laminated thermoplastic sheet 200 is moved, via the frame, into one or more heating stations, preferably including (see FIGS. 3A and 3B ) an optional pre-heating station 202 at Block 106 a and a main heating station 204 at Block 106 b , wherein the pre-heating station, when present, provides partial heating to the sheet in advance of the main heating station. Preferably, both the class “A” side A of the sheet and the opposite class “B” side B of the sheet are each heated by respective heater banks 206 ap , 206 bp , 206 am , 206 bm . The heaters of the heater banks may be, for example, quartz, calrod, ceramic and or halogen. The main heater station 204 heats the laminated thermoplastic sheet 200 into a moldably softened state so that is ready for being thermoformed.
If Block 106 a is utilized, wherein pre-heating of the laminated thermoplastic sheet 200 is provided at the pre-heating station 202 , then the sheet is heated thereat for between about 1 and 3 minutes to attain a sheet temperature of about 250 degrees F. Thereupon, the laminated thermoplastic sheet 200 is shuttled to the main heating station 204 .
At Block 106 b , the laminated thermoplastic sheet 200 is heated in the main heating station 204 preferably as follows. The class “B” side B of the sheet is spaced from heater bank 206 bm a distance between preferably 7 inches and 24 inches and is heated to about 400 degrees Fahrenheit (degrees F.). The class “A” side A of the sheet is spaced from heater bank 206 am a distance preferably between 12 inches and 32 inches. The laminated thermoplastic sheet 200 is heated for a period of time of preferably between 1 and 5 minutes or until the class “A” side A of the sheet attains a temperature ranging from between about 280 and 350 degrees F., more preferably between about 290 and 330 degrees F., and yet more preferably between about 300 and 315 degrees F. The heater bank temperature is controlled by an infrared sensor indicating the temperature of the class “A” side A of the sheet.
At Block 108 the heated laminated thermoplastic sheet 200 is delivered, via the frame, to a thermoformer 208 (see FIG. 3C ). The thermoformer 208 has two components which are mutually separable and sealable: a vacuum box component 210 and a pressure box component 212 . In this regard, the laminated thermoplastic sheet 200 is oriented such that the class “A” side A thereof faces toward the pressure box component 212 , and the class “B” side B thereof faces toward the mold surface 224 .
The vacuum box component 210 includes a vacuum box wall 214 which defines a vacuum box 230 , a selectively movable inner support, a selectively movable mold 218 , and a vacuum source 220 connected to the vacuum box via a vacuum conduit 222 which passes through the vacuum box wall. The mold 218 is, for example, composed of poured aluminum which is cut back to size, surface treated and sand blasted, and includes a mold surface 224 of a predetermined shape to which the laminated thermoplastic sheet 200 is to be formingly shaped. The mold further has a plurality of coolant lines 228 through which a liquid coolant flows, wherein the coolant lines may be in multiple zones, preferably between 2 and 4 zones, for cooling the mold surface. The vacuum source is preferably capable of providing a vacuum of at least 30 inches of mercury (inches of Hg).
The pressure box component 212 includes a pressure box wall 240 which defines a pressure box 260 , a source of compressed air 242 , an air valve 244 , an air chiller 246 , an air port 262 at the pressure box wall, an air pressure regulation valve 264 , which may be incorporated with a dump valve 248 , in the pressure box wall, and, preferably, an auxiliary source of compressed air 250 , an auxiliary air valve 252 and an auxiliary air port 254 at the pressure box wall. The air chiller 246 cools the compressed air exiting from the source of compressed air 242 , and may, for nonlimiting example, be a refrigeration device (as for example an air conditioning unit and/or a heat exchanger) 246 a and/or a throttling valve 246 b for cooling by the well-known Joule-Thomson effect in which rapid expansion of a gas produces cooling thereof. The dump valve 248 is preferably in the form of a 4 inch air actuated ball valve. The source of compressed air 242 and the auxiliary source of compressed air 250 are preferably capable of providing a high cubic foot per minute air flow at a pressure of at least 50 pounds per square inch above atmospheric pressure (psi). In this regard, the airflow rate of the chilled compressed air is sufficient to maintain a predetermined chilled temperature, discussed hereinbelow, within the pressure box.
The vacuum box and pressure box components 210 , 212 are movable toward and away from each other, preferably the vacuum box component being stationary, wherein when in a mutually separated state, as shown at FIGS. 3C and 3G , the laminated thermoplastic sheet is movable into and out of the thermoformer 208 , and wherein when in a mutually closed state, the mutual perimeters 214 p , 240 p of the vacuum box wall 214 and the pressure box wall 240 , respectively provide an air tight seal therebetween.
Operation of the aforementioned components is preferably controlled by a programmable microprocessor Mp, shown at FIG. 2 .
Returning to Block 108 , at FIG. 3D the vacuum box and pressure box components 210 , 212 are bought together into the aforementioned closed state, whereat the perimeters 214 p , 240 p provide an air tight seal therebetween inclusive of the laminated thermoplastic sheet 200 . With the laminated thermoplastic sheet 200 still in the aforementioned heated state provided by Block 106 , thermoforming of the sheet is then performed at the thermoformer 208 , as follows.
At Block 108 a , cooling liquid (as for example water) is circulated through the coolant lines 228 .
Next, at Block 108 b , the vacuum source 220 is activated, drawing down a vacuum in the vacuum box 230 of from between zero and 30 inches of Hg, more preferably of between 10 and 25 inches of Hg, and most preferably of between 18 and 22 inches of Hg. As shown sequentially at FIGS. 3D and 3E , the vacuum causes the laminated thermoplastic sheet 200 to be sucked onto the mold surface 224 and thereupon assume the shape of the mold surface.
Simultaneously with execution of Block 108 b , at Block 108 c the auxiliary air valve 252 is opened and the auxiliary source of compressed air 250 thereupon delivers compressed air CA to the pressure box 260 of the pressure box component 212 . The auxiliary source of compressed air 250 provides a rapid pressurization in the pressure box 260 of between zero to 40 psi, more preferably of between 5 and 30 psi, and yet more preferably between 10 and 25 psi. The pressure of the compressed air CA in the pressure box 260 is regulated by the pressure regulation valve 264 , which may be incorporated in the air valve 244 , in the auxiliary air valve 252 , in the dump valve 248 (as mentioned and shown merely by way of example) or be a separate pressure regulation valve in the pressure box wall 240 .
As shown sequentially at FIGS. 3D and 3E , the pressure of the compressed air CA pressing the laminated thermoplastic sheet 200 onto the mold surface 224 simultaneously acts with the sucking action of the vacuum source 220 drawing the laminated thermoplastic sheet onto the mold surface in Block 108 b , to thereby enhance the forming detail of the laminated thermoplastic sheet with respect to surface details of the mold surface. The pressure of the compressed air CA at Block 108 c is held in the pressure box 260 for between zero and 40 seconds, more preferably for between 5 and 30 seconds, and yet more preferably for between 7 and 15 seconds.
Once the aforesaid time of pressurization at Block 108 c has expired, the auxiliary source of compressed air 250 is shut-off by the auxiliary air valve 252 being closed and the dump valve 248 being opened so as to dump the compressed air CA from the pressure box, as shown at FIG. 3E , to environs outside the thermoformer 208 .
Next, at Block 108 d , the dump valve 248 is closed and chilled compressed air CCA is introduced into the pressure box, via opening of the air valve 244 , to allow, as shown at FIG. 3F , compressed air from the compressed air source to pass through the air chiller 246 flushingly into the pressure box 260 . The pressure value of the chilled compressed air CCA is basically the same as that indicated hereinabove for the compressed air CA. The chilled compressed air CCA flushes at a flow rate into and out of the pressure box 260 so that, at maintained pressure, the temperature of the chilled compressed air in the pressure box is maintained at between 32 and 70 degrees F., more preferably between 32 and 60 degrees F., and yet more preferably between 32 and 50 degrees F.
The chilled compressed air CCA is applied for between 1 and 15 seconds, more preferably between 5 and 10 seconds, the time being determined by the desire to chill the class “A” side A of the laminated thermoplastic sheet 200 to a temperature of 200 degrees F., more preferably to below 190 degrees F., wherein an infrared temperature sensor senses the temperature of the class “A” side of the sheet, and the microprocessor controls the rate of temperature lowering of the sheet to ensure retention of gloss of the class “A” side thereof. In this regard, critical to the success of forming a class “A” part is the rate of cooling of the class “A” side (or surface) A of the laminated thermoplastic sheet 200 . The class “A” side temperature needs to be reduced to less than 190 degrees F. within 30 seconds of initial forming on the mold, more preferably within 20 seconds and still more preferably within 15 seconds. Once forming of the laminated thermoplastic sheet is completed, the air valve 244 is closed.
At Block 110 , the laminated thermoplastic sheet 200 has fully formed on the mold surface and has now become cooled, whereupon, as shown at FIG. 3G , the vacuum box and pressure box components 210 , 212 are again separated, so that the formed laminated thermoplastic sheet 200 ′ can be removed from the thermoformer 208 .
Once the formed laminated thermoplastic sheet is removed from the thermoformer, it is moved to a next station where it is removed, in a conventional manner, from the frame, put onto a cooling fixture, and then moved to a trimming station which trims it to size to provide a completed part at Block 112 .
While the above described method of thermoforming involved an auxiliary source of compressed air 250 , it is possible to alternatively use the source of compressed air 242 as a singular source of compressed air to the pressure box, as for example depicted at FIGS. 4A and 4B . In this regard, the air from the source of compressed air 242 may be chilled through the air chiller 246 initially as the singular source of compressed air 242 supplies at all times chilled compressed air to the pressure box 260 , as shown at FIG. 4A (in this case, the compressed air comprises chilled compressed air). Alternatively in this regard, an initial shot of compressed air may be delivered as described hereinabove using only the source of compressed air 242 , wherein a switch valve 244 ′ directs the compressed air initially through an alternate conduit with a port 254 ′, then after the laminated thermoplastic sheet has initially formed, the switch valve directs the compressed air through the refrigeration device 246 to provide the chilled compressed air at the portal 262 ′ in the manner described hereinabove, as shown at FIG. 4B .
Utilizing the aforedescribed thermoforming process 100 according to the present invention, a laminated thermoplastic sheet can be thermoformed into a part with a retained gloss above 70 and distinctness of image (DOI) greater than 80, the requirement for class “A” parts for automotive industry.
The following examples were performed and are provided for illustrative purposes. Gloss was measured using a BYK-Gardner (of Columbia, Md. 21046) micro tri-gloss meter model 4524 at a 60 degrees surface angle. In each example, the laminated thermoplastic sheet was a TPO sheet having a composition similar to that shown in FIG. 1 , and having a total thickness of about 140 thousandths of an inch.
EXAMPLE 1
PROCESSING CONDITIONS:
VALUES:
Class “A” side temp.
330 degrees F.
Class “B” side temp.
430 degrees F.
Compressed air temp.
Not applicable
Chilled compressed air temp.
Not applicable
Air pressure in pressure box
None
Vacuum
20 inches of Hg
Vacuum time
about 60 seconds
Mold coolant temp.
75 to 90 degrees F.
60° gloss reading before molding
at or above 70
60° gloss reading after molding
50
Mold cooling temperature
75 to 90 degrees F.
Quality of part, comments
Webbing, poor quality, lost gloss
Example 1 illustrates prior art thermoforming process conditions, wherein the hoped for outcome should a high gloss class “A” part; however, poor part quality and low gloss resulted. There was no compressed air in the pressure box.
EXAMPLE 2
PROCESSING CONDITIONS:
VALUES:
Class “A” side temp.
320 degrees F.
Class “B” side temp.
420 degrees F.
Compressed air temp.
about 90 degrees F.
Chilled compressed air temp.
Not applicable
Air pressure in pressure box
20 psi
Compressed air time
about 60 seconds
Vacuum
20 inches of Hg
Vacuum time
about 60 seconds
Mold coolant temp.
75 to 90 degrees F.
60° gloss reading before molding
at or above 70
60° gloss reading after molding
50
Mold cooling temperature
75 to 90 degrees F.
Quality of part, comments
poor forming, lost gloss
Example 2 illustrates a second example of the prior art which is an adjustment of the process illustrated in Example 1, wherein ambient temperature compressed air was introduced into the pressure box. Although temperatures were lowered, the results were as in Example 1, poor part quality and low gloss.
EXAMPLE 3
PROCESSING CONDITIONS:
VALUES:
Class “A” side temp.
310 degrees F.
Class “B” side temp.
400 degrees F.
Compressed air temp.
about 90 degrees F.
Chilled compressed air temp.
70 degrees F.
Air pressure in pressure box
20 psi
Compressed air time
7 to 12 seconds
Chilled compressed air time
53 to 48 seconds
Vacuum
20 inches of Hg
Vacuum time
about 60 seconds
Mold coolant temp.
75 to 90 degrees F.
60° gloss reading before molding
at or above 70
60° gloss reading after molding
60
Mold cooling temperature
75 to 90 degrees F.
Quality of part, comments
good forming, lost gloss
In Example 3, by adding some chilled compressed air into the pressure box, the definition of the formed part was improved, but the gloss was still inferior.
EXAMPLE 4
PROCESSING CONDITIONS:
VALUES:
Class “A” side temp.
310 degrees F.
Class “B” side temp.
400 degrees F.
Compressed air temp.
about 90 degrees F.
Chilled compressed air temp.
50 degrees F.
Air pressure in pressure box
20 psi
Compressed air time
7 to 12 seconds
Chilled compressed air time
53 to 48 seconds
Vacuum
20 inches of Hg
Vacuum time
about 60 seconds
Mold coolant temp.
75 to 90 degrees F.
60° gloss reading before molding
at or above 70
60° gloss reading after molding
at or above 70
Mold cooling temperature
75 to 90 degrees F.
Quality of part, comments
good forming, retained gloss
Example 4 was carried out according to the thermoforming method 100 of the present invention, as outlined hereinabove. The forming detail and retention of gloss of the class “A” side was excellent.
EXAMPLE 5
The process as described above in Example 4 was followed, but the class “A” side of the laminated thermoplastic sheet was cooled such that the class “A” side did not reach 190 degrees F. within 15 seconds. By not switching to chilled air for greater than 15 seconds, the gloss of the part was reduced to less than a value of 70. This illustrates the importance of cooling the class “A” side of the laminated thermoplastic sheet below 190 degrees F. within 15 seconds. Not achieving this timing causes the gloss of the class “A” side to fall below 70.
By contrast, the process as described in Example 4 involved the chilled compressed air being introduced in less than 7 to 12 seconds into the pressure box, resulting a gloss value being retained above 70. Accordingly, it is anticipated that incorporating the chilled compressed air initially at the pressurization stage will further enhance or sustain the final gloss of the class “A” side of the laminated thermoplastic sheet.
To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.
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A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. A thermoformer has a vacuum box component which includes a mold, and a pressure box component which is selectively sealable in relation to the vacuum box component. A heated laminated thermoplastic sheet is placed in the thermoformer, the class “A” side thereof facing away from the mold, and the thermoformer sealed. Vacuum is applied to the vacuum box component and simultaneously air pressure is applied to the pressure box component, including application of chilled compressed air, resulting in forming of the sheet on the mold and controlled cooling of the sheet which preserves its class “A” finish and high gloss.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/299,909 and U.S. patent application Ser. No. 14/299,915, both filed Jun. 9, 2014, which are continuations of U.S. patent application Ser. No. 13/777,331, filed Feb. 26, 2013 and issued as U.S. Pat. No. 8,866,396 on Oct. 21, 2014, which is a continuation of U.S. patent application Ser. No. 12/965,019, filed Dec. 10, 2010 and issued as U.S. Pat. No. 8,382,327 on Feb. 26, 2013, which is a continuation of U.S. patent application Ser. No. 11/085,744, filed Mar. 21, 2005 and issued as U.S. Pat. No. 8,247,985 on Aug. 21, 2012, which is a continuation of U.S. patent application Ser. No. 09/782,375, filed Feb. 12, 2001 and issued as U.S. Pat. No. 7,049,761 on May 23, 2006, which claims the benefit of U.S. Provisional Application No. 60/181,744 filed Feb. 11, 2000.
FIELD OF THE INVENTION
The present invention relates to a light tube illuminated by LEDs (light emitting diodes) which are packaged inside the light tube and powered by a power supply circuit.
BACKGROUND OF THE INVENTION
Conventional fluorescent lighting systems include fluorescent light tubes and ballasts. Such lighting systems are used in a variety of locations, such as buildings and transit buses, for a variety of lighting purposes, such as area lighting or backlighting. Although conventional fluorescent lighting systems have some advantages over known lighting options, such as incandescent lighting systems, conventional fluorescent light tubes and ballasts have several shortcomings. Conventional fluorescent light tubes have a short life expectancy, are prone to fail when subjected to excessive vibration, consume high amounts of power, require a high operating voltage, and include several electrical connections which reduce reliability. Conventional ballasts are highly prone to fail when subjected to excessive vibration. Accordingly, there is a desire to provide a light tube and power supply circuit which overcome the shortcomings of conventional fluorescent lighting systems. That is, there is a desire to provide a light tube and power supply circuit which have a long life expectancy, are resistant to vibration failure, consume low amounts of power, operate on a low voltage, and are highly reliable. It would also be desirable for such a light tube to mount within a conventional fluorescent light tube socket.
SUMMARY OF THE INVENTION
Embodiments of a replacement light tube for replacing a fluorescent light tube are disclosed herein. In one embodiment, the replacement light tube includes an elongate tubular housing having a first end and a second end and a first end cap and a second end cap disposed on the first end and the second end, respectively, each configured to fit with a socket for the fluorescent light tube. The replacement light tube also includes a rigid support structure having a planar portion having a first surface extending within the elongate tubular housing between the first end and the second end and having spaced-apart sidewalls extending away from the first surface and extending within the elongate tubular housing between the first end and the second end. At least a portion of the sidewalls are in contact with an interior surface of the elongate tubular housing. Further, the replacement light tube includes a plurality of white light emitting diodes supported only by a second surface of the planar portion opposite to the first surface and between the first end and the second end. The plurality of light emitting diodes are arranged to emit light through the elongate tubular housing.
In another embodiment, the replacement light tube includes an elongate tubular housing having a first end and a second end and a first end cap and a second end cap disposed on the first end and the second end, respectively, each configured to fit with a socket for the fluorescent light tube and comprising a respective pair of electrical bi-pin connectors. The replacement light tube also includes a rigid support structure having a planar portion having a first surface extending within the elongate tubular housing between the first end and the second end and having spaced-apart sidewalls extending away from the first surface and extending within the elongate tubular housing between the first end and the second end. At least a portion of the sidewalls are in contact with an interior surface of the elongate tubular housing. Further, the replacement light tube includes a plurality of white light emitting diodes supported only by a second surface of the planar portion opposite to the first surface and between the first end and the second end. The plurality of light emitting diodes are arranged to emit light through the elongate tubular housing. The support structure divides the elongate tubular housing into a first space in which the plurality of light emitting diodes are housed and a second space defined by the planar portion, the sidewalls and the interior surface of the elongate tubular housing.
In another embodiment, the replacement light tube includes an elongate tubular housing having a first end and a second end, and a first end cap and a second end cap disposed on the first end and the second end, respectively, each configured to fit with a socket for the fluorescent light tube. The replacement light tube also includes a rigid support structure having a planar portion having a first surface extending within the elongate tubular housing between the first end and the second end and having spaced-apart sidewalls extending away from the first surface and extending within the elongate tubular housing between the first end and the second end. At least a portion of the sidewalls are in contact with an interior surface of the elongate tubular housing. Further, the replacement light tube includes a plurality of white light emitting diodes supported by the first surface between the first end and the second end. The plurality of light emitting diodes are arranged to emit light through the elongate tubular housing. The replacement light tube further includes a power supply circuit including a pulse width modulator and a current limiter. The power supply circuit is packaged within one of the end caps.
In another embodiment, the replacement light tube includes an elongate tubular housing having a first end and a second end and a first end cap and a second end cap disposed on the first end and the second end, respectively, each configured to fit with a socket for the fluorescent light tube. The replacement light tube also includes a rigid support structure having a planar portion having a first surface extending within the elongate tubular housing between the first end and the second end and having spaced-apart sidewalls extending away from the planar portion and extending within the elongate tubular housing between the first end and the second end. At least a portion of the sidewalls are in contact with an interior surface of the elongate tubular housing. The planar portion is integral with the sidewalls. Further, the replacement light tube includes a plurality of white light emitting diodes supported by the first surface between the first end and the second end. The plurality of light emitting diodes are arranged to emit light through the elongate tubular housing. The replacement light tube further includes a power supply circuit including a pulse width modulator and a current limiter. At least a portion of the power supply circuit is packaged within the elongate tubular housing or one of the end caps.
These and other embodiments will be discussed in additional detail hereafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 is a line drawing showing a light tube, in perspective view, which in accordance with the present invention is illuminated by LEDs packaged inside the light tube;
FIG. 2 is a perspective view of the LEDs mounted on a circuit board;
FIG. 3 is a cross-sectional view of FIG. 2 taken along lines 3 - 3 ;
FIG. 4 is a fragmentary, perspective view of one embodiment of the present invention showing one end of the light tube disconnected from one end of a light tube socket;
FIG. 5 is an electrical block diagram of a first power supply circuit for supplying power to the light tube;
FIG. 6 is an electrical schematic of a switching power supply type current limiter;
FIG. 7 is an electrical block diagram of a second power supply circuit for supplying power to the light tube;
FIG. 8 is an electrical block diagram of a third power supply circuit for supplying power to the light tube;
FIG. 9 is a fragmentary, perspective view of another embodiment of the present invention showing one end of the light tube disconnected from one end of the light tube socket; and
FIG. 10 is an electrical block diagram of a fourth power supply circuit for supplying power to the light tube.
DETAILED DESCRIPTION
FIG. 1 is a line drawing showing a light tube 20 in perspective view. In accordance with the present invention, the light tube 20 is illuminated by LEDs 22 packaged inside the light tube 20 . The light tube 20 includes a cylindrically shaped bulb portion 24 having a pair of end caps 26 and 28 disposed at opposite ends of the bulb portion. Preferably, the bulb portion 24 is made from a transparent or translucent material such as glass, plastic, or the like. As such, the bulb material may be either clear or frosted.
In a preferred embodiment of the present invention, the light tube 20 has the same dimensions and end caps 26 and 28 (e.g. electrical male bi-pin connectors, type G13) as a conventional fluorescent light tube. As such, the present invention can be mounted in a conventional fluorescent light tube socket.
The line drawing of FIG. 1 also reveals the internal components of the light tube 20 . The light tube 20 further includes a circuit board 30 with the LEDs 22 mounted thereon. The circuit board 30 and LEDs 22 are enclosed inside the bulb portion 24 and the end caps 26 and 28 .
FIG. 2 is a perspective view of the LEDs 22 mounted on the circuit board 30 . A group of LEDs 22 , as shown in FIG. 2 , is commonly referred to as a bank or array of LEDs. Within the scope of the present invention, the light tube 20 may include one or more banks or arrays of LEDs 22 mounted on one or more circuit boards 30 . In a preferred embodiment of the present invention, the LEDs 22 emit white light and, thus, are commonly referred to in the art as white LEDs. In FIGS. 1 and 2 , the LEDs 22 are mounted to one surface 32 of the circuit board 30 . In a preferred embodiment of the present invention, the LEDs 22 are arranged to emit or shine white light through only one side of the bulb portion 24 , thus directing the white light to a predetermined point of use. This arrangement reduces light losses due to imperfect reflection in a convention lighting fixture. In alternative embodiments of the present invention, LEDs 22 may also be mounted, in any combination, to the other surfaces 34 , 36 , and/or 38 of the circuit board 30 .
FIG. 3 is a cross-sectional view of FIG. 2 taken along lines 3 - 3 . To provide structural strength along the length of the light tube 20 , the circuit board 30 is designed with a H-shaped cross-section. To produce a predetermined radiation pattern or dispersion of light from the light tube 20 , each LED 22 is mounted at an angle relative to adjacent LEDs and/or the mounting surface 32 . The total radiation pattern of light from the light tube 20 is effected by (1) the mounting angle of the LEDs 22 and (2) the radiation pattern of light from each LED. Currently, white LEDs having a viewing range between 6° and 45° are commercially available.
FIG. 4 is a fragmentary, perspective view of one embodiment of the present invention showing one end of the light tube 20 disconnected from one end of a light tube socket 40 . Similar to conventional fluorescent lighting systems and in this embodiment of the present invention, the light tube socket 40 includes a pair of electrical female connectors 42 and the light tube 20 includes a pair of mating electrical male connectors 44 .
Within the scope of the present invention, the light tube 20 may be powered by one of four power supply circuits 100 , 200 , 300 , and 400 . A first power supply circuit includes a power source and a conventional fluorescent ballast. A second power supply circuit includes a power source and a rectifier/filter circuit. A third power supply circuit includes a DC power source and a PWM (Pulse Width Modulation) circuit. A fourth power supply circuit powers the light tube 20 inductively.
FIG. 5 is an electrical block diagram of a first power supply circuit 100 for supplying power to the light tube 20 . The first power supply circuit 100 is particularly adapted to operate within an existing, conventional fluorescent lighting system. As such, the first power supply circuit 100 includes a conventional fluorescent light tube socket 40 having two electrical female connectors 42 disposed at opposite ends of the socket. Accordingly, a light tube 20 particularly adapted for use with the first power supply circuit 100 includes two end caps 26 and 28 , each end cap having the form of an electrical male connector 44 which mates with a corresponding electrical female connector 42 in the socket 40 .
The first power supply circuit 100 also includes a power source 46 and a conventional magnetic or electronic fluorescent ballast 48 . The power source 46 supplies power to the conventional fluorescent ballast 48 .
The first power supply circuit 100 further includes a rectifier/filter circuit 50 , a PWM circuit 52 , and one or more current-limiting circuits 54 . The rectifier/filter circuit 50 , the PWM circuit 52 , and the one or more current-limiting circuits 54 of the first power supply circuit 100 are packaged inside one of the two end caps 26 or 28 of the light tube 20 .
The rectifier/filter circuit 50 receives AC power from the ballast 48 and converts the AC power to DC power. The PWM circuit 52 receives the DC power from the rectifier/filter circuit 50 and pulse-width modulates the DC power to the one or more current-limiting circuits 54 . In a preferred embodiment of the present invention, the PWM circuit 52 receives the DC power from the rectifier/filter circuit 50 and cyclically switches the DC power on and off to the one or more current-limiting circuits 54 . The DC power is switched on and off by the PWM circuit 52 at a frequency which causes the white light emitted from the LEDs 22 to appear, when viewed with a “naked” human eye, to shine continuously. The PWM duty cycle can be adjusted or varied by control circuitry (not shown) to maintain the power consumption of the LEDs 22 at safe levels.
The DC power is modulated for several reasons. First, the DC power is modulated to adjust the brightness or intensity of the white light emitted from the LEDs 22 and, in turn, adjust the brightness or intensity of the white light emitted from the light tube 20 . Optionally, the brightness or intensity of the white light emitted from the light tube 20 may be adjusted by a user. Second, the DC power is modulated to improve the illumination efficiency of the light tube 20 by capitalizing upon a phenomenon in which short pulses of light at high brightness or intensity to appear brighter than a continuous, lower brightness or intensity of light having the same average power. Third, the DC power is modulated to regulate the intensity of light emitted from the light tube 20 to compensate for supply voltage fluctuations, ambient temperature changes, and other such factors that affect the intensity of white light emitted by the LEDs 22 . Fourth, the DC power is modulated to raise the variations of the frequency of light above the nominal variation of 120 to 100 Hz thereby reducing illumination artifacts caused by low frequency light variations, including interactions with video screens. Fifth, the DC power may optionally be modulated to provide an alarm function wherein light from the light tube 20 cyclically flashes on and off.
The one or more current-limiting circuits 54 receive the pulse-width modulated or switched DC power from the PWM circuit 52 and transmit a regulated amount of power to one or more arrays of LEDs 22 . Each current-limiting circuit 54 powers a bank of one or more white LEDs 22 . If a bank of LEDs 22 consists of more than one LED, the LEDs are electrically connected in series in an anode to cathode arrangement. If brightness or intensity variation between the LEDs 22 can be tolerated, the LEDs can be electrically connected in parallel.
The one or more current-limiting circuits 54 may include (1) a resistor, (2) a current-limiting semiconductor circuit, or (3) a switching power supply type current limiter.
FIG. 6 is an electrical schematic of a switching power supply type current limiter 56 . The limiter 56 includes an inductor 58 , electrically connected in series between the PWM circuit 52 and the array of LEDs 22 , and a power diode 60 , electrically connected between ground 62 and a PWM circuit/inductor node 64 . The diode 60 is designed to begin conduction after the PWM circuit 52 is switched off. In this case, the value of the inductor 58 is adjusted in conjunction with the PWM duty cycle to provide the benefits described above. The switching power supply type current limiter 56 provides higher power efficiency than the other types of current-limiting circuits listed above.
FIG. 7 is an electrical block diagram of a second power supply circuit 200 for supplying power to the light tube 20 . Similar to the first power supply circuit 100 , the second power supply circuit 200 includes a conventional fluorescent light tube socket 40 having two electrical female connectors 42 disposed at opposite ends of the socket 40 . Accordingly, a light tube 20 particularly adapted for use with the second power supply circuit 200 includes two end caps 26 and 28 , each end cap having the form of an electrical male connector 44 which mates with a corresponding electrical female connector 42 in the socket 40 .
In the second power supply circuit 200 , the power source 46 supplies power directly to the rectifier/filter circuit 50 . The rectifier/filter circuit 50 , the PWM circuit 52 , and the one or more current-limiting circuits 54 operate as described above to power the one or more arrays of LEDs 22 . The rectifier/filter circuit 50 , the PWM circuit 52 , and the one or more current-limiting circuits 54 of the second power supply circuit 200 are preferably packaged inside the end caps 26 and 28 or the bulb portion 24 of the light tube 20 or inside the light tube socket 40 .
FIG. 8 is an electrical block diagram of a third power supply circuit 300 for supplying power to the light tube 20 . Similar to the first and second power supply circuits 100 and 200 , the third power supply circuit 300 includes a conventional fluorescent light tube socket 40 having two electrical female connectors 42 disposed at opposite ends of the socket 40 . Accordingly, a light tube 20 particularly adapted for use with the third power supply circuit 300 includes two end caps 26 and 28 , each end cap having the form of an electrical male connector 44 which mates with a corresponding electrical female connector 42 in the socket 40 .
The third power supply circuit 300 includes a DC power source 66 , such as a vehicle battery. In the third power supply circuit 300 , the DC power source 66 supplies DC power directly to the PWM circuit 52 . The PWM circuit 52 and the one or more current-limiting circuits 54 operate as described above to power the one or more arrays of LEDs 22 . In the third power supply circuit 300 , the PWM circuit 52 is preferably packaged in physical location typically occupied by the ballast of a conventional fluorescent lighting system while the one or more current-limiting circuits 54 and LEDs 22 are preferably packaged inside the light tube 20 , in either one of the two end caps 26 or 28 or the bulb portion 24 .
FIG. 9 is a fragmentary, perspective view of another embodiment of the present invention showing one end of the light tube 20 disconnected from one end of the light tube socket 40 . In this embodiment of the present invention, the light tube socket 40 includes a pair of brackets 68 and the light tube 20 includes a pair of end caps 26 and 28 which mate with the brackets 68 .
FIG. 10 is an electrical block diagram of a fourth power supply circuit 400 for supplying power to the light tube 20 . Unlike the first, second, and third power supply circuits 100 , 200 , and 300 which are powered through direct electrical male and female connectors 44 and 42 , the fourth power supply circuit 400 is powered inductively. As such, the fourth power supply circuit 400 includes a light tube socket 40 having two brackets 68 disposed at opposite ends of the socket 40 . At least one bracket 68 includes an inductive transmitter 70 . Accordingly, a light tube 20 particularly adapted for use with the fourth power supply circuit 400 has two end caps 26 and 28 with at least one end cap including an inductive receiver or antenna 72 . When the light tube 20 is mounted in the light tube socket 40 , the at least one inductive receiver 72 in the light tube 20 is disposed adjacent to the at least one inductive transmitter 70 in the light tube socket 40 .
The fourth power supply circuit 400 includes the power source 46 which supplies power to the at least one inductive transmitter 70 in the light tube socket 40 . The at least one transmitter 70 inductively supplies power to the at least one receiver 72 in one of the end caps 26 and/or 28 of the light tube 20 . The at least one inductive receiver 72 supplies power to the rectifier/filter circuit 50 . The rectifier/filter circuit 50 , PWM circuit 52 , and the one or more current-limiting circuits 54 operate as described above to power the one or more arrays of LEDs 22 . In this manner, the light tube 20 is powered without direct electrical connection.
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A replacement light tube for replacing a fluorescent light tube includes an elongate tubular housing having first and second ends, first and second end caps disposed thereon, each configured to fit with a socket for the fluorescent light tube, and a rigid support structure having a planar portion having a first surface extending within the elongate tubular housing between the first and second ends and having spaced-apart sidewalls extending away from the first surface and extending within the housing between the first and second ends. At least a portion of the sidewalls are in contact with an interior surface of housing. A plurality of white light emitting diodes are supported only by a second surface of the planar portion opposite to the first surface and between the first and second ends, and are arranged to emit light through the housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a safety device for a sewing machine, and more particularly to a safety interlock mechanism which prevents the sewing machine from malfunctioning.
2. Description of the Related Art
FIG. 9 shows a currently available and well-known sewing machine M which is capable of converting the stitch mode from "one needle two thread stitches A" (chain stitches) as shown in FIG. 7 to "one needle three thread stitches B" (overlock stitches) as shown in FIG. 8, and vice versa. The sewing machine M as shown includes needle N, upper and lower loopers (not shown) incorporated in a looper cover 6, a control unit for controlling the drives of these members, and a motor as a drive source.
A controller 13 in the form of a foot pedal is manipulated to drive the sewing machine M through the motor and to adjust the drive speed thereof. As is well known, the lower looper for the sewing machine is adapted to perform its sewing operation below a work table 5, whereas the upper looper is adapted to perform a predetermined sewing operation above the work table 5. A change-over dial or knob 1 selects the stitch mode as either "one needle two thread stitches A" or "one needle thread stitches B."
For formation of the "one needle two thread stitches A", the change-over dial or knob 1 is set to select a mark A on the machine cover, indicative of the "one needle two thread stitches A" and at the same time a second work table 3 as seen from FIG. 9 is installed in the sewing machine M. This will allow the sewing machine M to drive the needle N and the lower looper, rendering them ready for formation of the "one needle two thread stitches A" whereas the upper looper is lowered and inactivated in a position where the upper looper does not abut against the second work table 3.
When the "one needle three thread stitches B" mode is desired, the change-over dial or knob 1 is set to select the other mark B on the machine cover, indicative of the "one needle three thread stitches B," and at the same time a chip guard cover 4 (FIG. 1) is attached to the sewing machine M. This will allow the sewing machine M to drive the needle N and the upper and lower loopers, rendering them ready for formation of the "one needle three thread stitches B".
The aforementioned conventional sewing machine has disadvantages in that the upper looper is liable to collide with the second work table 3 if the change-over knob 1 is set to select the mark B indicative of the "one needle three thread stitches" with the second work table 3 attached to the sewing machine M as illustrated in FIG. 9. This may be dangerous to the operator since the second work table 3, the upper looper as well as the sewing machine M can break down and scatter fragments, thereby injuring the operator.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a safety device for a sewing machine, which is configured to overcome the aforementioned disadvantages inherent in the prior art.
Another object of the invention is to provide a safety device for sewing machines, which includes a stitch forming signal generator means adapted to transmit a "one needle three thread stitch" signal, and which is designed to stop the sewing machine regardless of whether the controller is actuated, so that the sewing machine is prevented from malfunctioning when the second work table is installed and the "one needle three thread stitch" signal is transmitted.
A further object of the invention is to provide a safety device for sewing machines, which facilitates conversion of stitches from one mode to another mode by appropriately preventing the motor from being driven, particularly if the sewing machine is inadvertently operated when the change-over dial or knob is switched.
These and other objects of the invention are accomplished by providing a safety device with a stitch forming signal generator means for transmitting either a "one needle three thread stitch" signal or a "one needle two thread stitch" signal in association with the means for converting the stitches from one to the other mode, and a mounting-demounting signal generator means for transmitting a mounting signal or a demounting signal in association with mounting or demounting of a second work table whereby a motor is prevented from driving, regardless of whether the controller is operated, when the "one needle three thread signal" is transmitted by the stitch forming signal transmitter means, and the mounting signal is transmitted by the mounting and demounting signal generator means.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail below by way of reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view generally showing a safety device for a sewing machine, embodying the present invention;
FIG. 2 is a perspective view of the sewing machine partially broken away for the purpose of illustration of the interior thereof;
FIG. 3 is a perspective view of a second work table and showing the details of the structure;
FIG. 4 is a block diagram illustrating an overall arrangement of the safety device according to the invention;
FIG. 5 is a flow chart illustrating a sequence of operations of the safety device according to the invention;
FIG. 6 is a timing chart showing a sequence of the safety device according to the invention;
FIG. 7 is a front view of a workpiece as seamed by "one needle two thread stitches";
FIG. 8 is a front view of the workpiece as seamed by "one needle three thread stitches";
FIG. 9 is a conventional sewing machine which is provided with a second work table installed therein; and
FIG. 10 is a perspective view showing a change-over means incorporated in the sewing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be described hereinafter in conjunction with the accompanying drawings, particularly, FIGS. 1 through 6, wherein like reference characters designate like or corresponding parts throughout the views.
Referring to FIG. 1, a stitch forming signal generator means 2 transmits either a one needle three thread stitch signal or a one needle two thread stitch signal to a control unit of a sewing machine M is association with a mechanism 1 for change-over operation.
A looper cover is shown perspectively in FIG. 2 as being opened and is provided with a switching tongue 6a (FIG. 9) which is laterally moved to contact a spring 11, thereby disengaging a latch member 12a formed on a work table 5 from another latch member 12b disposed on the looper cover 6 to bring the latter into an open condition.
Upper and lower loopers 7 and 8, respectively, are connected to a drive means (not shown) for the sewing machine and adapted to actuate a predetermined drive. A looper cover switch 10 comprises a switch member 10a mounted below the work table 5, and a switch actuator 10b disposed on the looper cover 6. As a precaution, the switch member 10a is disengaged from the switch actuator 10b when the looper cover 6 is brought into the open condition so that the switch member 10b is off, thereby preventing the sewing machine M from driving.
The looper cover 6 is attached to a frame F which is provided with a mounting-demounting signal transmitter means S. When in contact with anything, this transmitter means S is turned to ON to send a mounting signal to the control unit, but when not in contact with anything it is turned to OFF to transmit a demounting signal to the control unit. A holder means 9 is disposed on the looper cover 6 for supporting or holding a chip guard cover 4 or the second work table 5 and comprises a clamp plate 9a, an end guide 9c, and a leaf spring 9b.
As is best shown in FIG. 2, the chip guard cover 4 is held in position by the end guide 9c to prevent the former from laterally slipping and is held down by the clamp plate 9a to engage the leaf spring 9b in a through hole 4a; that is, the chip guard cover 4 is supported in position by a hold-down means. When the chip guard cover is installed, the mounting-demounting signal generator means S transmits the demounting signal to the control unit since nothing contacts the generator means S, even when the looper cover 6 is closed.
The second work table 3, as perspectively shown in FIG. 3, comprises a workpiece supporting plate 3b, and a retainer 3c to be engaged with the holder means 9 by the leaf spring 9c which is fitted into a through hole 3a therein. The retainer 3c includes an engageable segment C horizontally extended therefrom. When the second work table 3 as held by the holder means 9 is brought into a sewing condition by closing the looper cover 6, the mounting-demounting signal generator means S is turned to ON to apply the mounting signal to the control means by engaging the engageable segment C with the mounting-demounting signal generator or transmitter means S.
Attention is now directed to FIG. 10 wherein a change-over means for controlling the upper looper is shown, which is disclosed in the copending U.S. patent application Ser. No. 07/866,404 filed Apr. 10, 1992 concurrently herewith (now U.S. Pat. No. 5,255,622) and entitled "Overlock Sewing Machine" that is assigned to the common assignee hereof and incorporated herein by reference.
An upper looper swing device comprises an upper looper support element, an upper looper drive element for driving the upper looper element, and a link assembly, which will be described hereinbelow. The upper looper swing device includes an upper looper shaft 17 rotatably supported on the sewing machine frame, an upper looper swing arm 18 one end of which is rotatably attached to the upper looper shaft 17, and an upper looper support arm 19 the lower end of which is pivoted to a free end of the upper looper swing arm 18. The upper looper 7 is fixed to the upper end of the upper looper support arm 19 which is guided by an upper looper slide bearing 20. Consequently, swing movement of the upper looper swing arm 18 in the direction of arrow a allows the lower looper 7 to effect its swing movement to a predetermined extent.
The upper looper drive mechanism or element provides an upper looper drive arm 21 secured to the upper looper shaft 17, an upper looper connecting arm 22 one end of which is fixed to the upper looper drive arm 21, and an upper looper swing rod 24 for connecting the upper looper connecting arm 22 to a main shaft 23. A ball-shaped member (not shown) is formed on one end, i.e., a projecting end of the upper looper connecting arm 22 and is so fitted in a bearing 25 formed on the lower end of the upper looper swing rod 24 as to afford a spheric motion. An eccentric cam (not shown) is rigidly mounted on the main shaft 23 and is rotatably fitted in a bearing 26 provided on the upper end of the upper looper swing rod 24. Subsequently, rotation of the main shaft 23 reciprocally rotates the upper looper drive arm 21, i.e., the upper loop shaft 17 about its axis in a predetermined angular range by means of the upper looper swing rod 24 and the upper looper connecting arm 22.
The link assembly serves to control swing movement of the lower looper shaft, viz., to impart or not impart such movement to the upper looper swing arm 18. The link assembly is composed of an upper looper interlocking arm 27 secured to the upper looper shaft 17, and a release element adapted for engaging or disengaging the upper looper arm 18 with the interlocking arm 27 of therefrom. The release element includes an upper looper release member 28, and an upper looper release pin 29 rigidly mounted on the release member 28. The upper looper release member 28 is slidable mounted on the upper looper shaft 17 longitudinally thereof. The upper looper release pin 29 is adapted to smoothly fit in notches 18a and 27a formed in the upper looper swing arm 18 and the interlocking arm 27. The upper looper release member 28 is moved by a motion shifter as described later, between a swing position where the release pin 29 engages with the interlocking arm 27 and a non-swing position where the pin 29 is out of engagement therewith. More specifically, in the swing position, the upper looper release pin 29 engages with the interlocking arm 27 and the upper looper swing arm 18 so that swing movement of the upper looper shaft 17 is imparted by the interlocking arm 27 to the swing arm 18, thereby swinging the upper looper 7. In the non-swing position, the release pin 29 is out of engagement with the interlocking arm 27 so that swing movement of the upper looper shaft 17 is not imparted to the swing arm 18. It is noted that in this instance the upper looper 7 assumes the lowermost position in the non-swing position.
As shown, a main shift arm 30 and an upper looper release shift arm 31 are formed into a release control means. The release shift arm 31 serves to connect the main shift arm 30 to the release member 28. The upper looper release shift arm 31 is adapted not only to rotatably support its central portion on a frame mounting plate (not shown) but also to pivot its one end to the main shift arm 30. An engageable pin 32 is fixed to the other end of the shift arm 31 and has its one end fitted in a groove (not shown) formed in the release member 28.
The motion shifter is formed by the change-over knob 1 disposed rearwardly of the sewing machine frame, a stitch conversion cam 33 secured to the shaft of the change-over dial or knob 1, and a stitch conversion lever 34 one end of which is in contact with the cam 33. In this configuration, rotation of the change-over knob 1 allows the main shift arm 30 to move longitudinally thereof through the conversion cam 33, the conversion lever 34, and a link means 35.
The main shift arm 30 is moved in the direction of an arrow b in such a manner that the shift arm 31 is rotated through the pin 32 to keep the release member 28 away from the swing arm 18. This will remove the release pin 29 out of a recess 27a in the interlocking arm 27 so that movement of the upper looper shaft 17 is not imparted to the swing arm 18.
FIG. 4 is block diagram illustrating an overall arrangement of the safety device. It should be understood that the control unit 14 is connected to the stitch forming signal transmitter or generator means 2, the mounting and demounting signal generator means S, the controller 13, and the looper cover switch 10. The control unit 14 is adapted to drive and stop a motor 16 via a motor drive device 15 which is response to the signal generated from the control unit.
The operation of the safety device will be apparent from the following description by reference to FIGS. 5 and 6, which depict a flow chart and a timing chart, respectively. Referring to FIG. 5, once the sewing machine M is energized the status of the looper cover switch 10 is determined (Step 1). If the looper cover switch 10 is OFF, the sewing machine M is prevented from driving the motor (Step 5). This is illustrated at instant t0-t3 of FIG. 6. During this period of time, the sewing machine M is not driven even if the controller 13 which serves to initiate the machine M and adjust the speed thereof is operated (t2 of FIG. 6).
If, however, the looper cover switch 10 is ON the mounting-demounting signal generator means S determines whether the second work table 3 is installed (Step 2). If a demounting signal (i.e., OFF) is indicated by the signal generator means S the controller 13, which controls the sewing speed, determines motor operation (Step 4). If the controller 13 is ON the sewing machine M motor is driven (Step 6), as at instants t4, t11 of FIG. 6. In contrast, if the controller 13 is OFF the sewing machine M motor is not driven (Step 5).
If the looper cover switch 10 is ON and the mounting-demounting signal generator means S outputs a mounting signal (i.e. ON) indicating that the second work table is mounted, then step 2 is followed by step 3 where the stitch forming signal transmitter generator means 2 determines which stitch is formed by means of the change-over dial 1.
In the case where the change-over dial 1 is set to the "one needle three thread stitch B", the sewing machine M stops (Step 5), as at instant t7 of FIG. 6. At this moment, the sewing machine M is not driven even if the controller 13 is turned to ON, as at instant t8 of FIG. 6. On the other hand, in the case where the change-over dial 1 is set to the "one needle two thread stitch A" (Step 3), sewing machine M motor operation is not inhibited and controller 13 effectively controls motor operation (Step 4). If the controller 13 is turned to ON, the sewing machine M motor is driven (Step 6), as at instants t4 and t6 of FIG. 6. In contrast, if the controller 13 is turned to OFF the sewing machine M motor stops (Step 5), as at instant t5 of FIG. 6.
Although the above description provides many specificities, these enabling details should not be construed as limiting the scope of the invention, and it will be readily understood by those persons skilled in the art that the present invention is susceptible to many modifications, adaptations, and equivalent implementations without departing from this scope. For example, the specific signal generating mechanisms can be based on many different types of electronic, mechanical, and optoelectronic devices. Also, the controller unit design may be, for example, based on hardwiring of passive components, different hardware implementations, or even software. Further, the integration of the described signalling and control means into various sewing machines is susceptible to myriad adaptations.
These and other changes can be made without departing from the spirit and the scope of the invention and without diminishing its attendant advantages. It is therefore intended that the present invention is not limited to the disclosed embodiments but should be defined in accordance with the claims which follow.
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For conversion of stitch mode from one stitch shape to the other stitch shape without interference with one another, a safety device for a sewing machine, as a safeguard against malfunction of the machine when conversion is made, is equipped with a stitch forming signal generator means for associating a signal with a stitch mode, a mounting-demounting signal generator means for associating a signal with table displacement, and a circuit for rendering a motor inactive irrespective of operation of a controller for the motor.
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BACKGROUND OF THE INVENTION
The present invention relates to a fuel injection system for an internal combustion engine.
A very effective method for reducing those components of the exhaust gas of an internal combustion engine which are detrimental to health, and especially for the reduction of NO x components, is the recycling of certain quantities of the exhaust gas. Adding a gas to the combustion process which does not take part in the combustion itself results in a reduction of the combustion temperature so that fewer nitrogen oxides NO x are produced. In addition, the expelled exhaust gas quantity is also reduced. However, because gas exchange processes take place, the efficiency of the internal combustion engine deteriorates. Furthermore, at low rpm and especially during idling operation, the smooth running of the engine is affected. On the other hand, it is possible, in the partial load domain, to recycle relatively large amounts of exhaust gas in order to keep the NO x emission low and still maintain smokeless combustion. However, a large quantity of exhaust gas must be recycled. Advantageously, during idling operation, the exhaust gas recycling is small. In addition, the combustion temperature is lower and hence also the nitrogen oxide emission. In the partial load domain, however, the nitrogen oxide emission is especially high and therefore especially dangerous because in city operation, for which the most stringent exhaust gas regulations are applicable, most driving is done in the partial load domain. The regulations with respect to cross-country driving are less stringent, and in this type of driving, under full load, maximum power is required and the accumulation of toxic exhaust gases is less.
OBJECTS AND SUMMARY OF THE INVENTION
It is, therefore, a general object of the present invention to provide a fuel injection system for an internal combustion engine which utilizes recycled exhaust gas to effect a high level of pollution control.
It is a more specific object of the present invention to provide a fuel injection system for diesel engines wherein the oxygen content of the fuel in the combustion chamber is always sufficiently high to ensure smokeless combustion and in which as much exhaust gas as possible is recycled in order to achieve a combustion particularly low in NO x emissions.
These and other objects are accomplished according to the present invention in that the system operates with exhaust gas recycling and includes, in addition to a suction tube and exhaust system, a recycle line and a device which controls the pressures in the suction tube and/or the exhaust system or the recycle line. The device determines the recycle flow rate and includes a control parameter which is compared with the fuel injection quantity by means of a regulating mechanism. In all cases, the regulating mechanism or regulator ensures that, for any amount of injected fuel, sufficient combustion air is available or conversely, that an appropriate amount of fuel is metered for the aspirated air quantity.
The suction tube includes an air measuring member and a manifold portion, and ahead of the air measuring member the prevailing pressure is at least substantially atmospheric pressure while in the region of the suction tube manifold, the prevailing pressure is the reduced pressure caused by the suction strokes of the pistons. Within the exhaust system, however, the prevailing pressure is a certain amount of positive gauge pressure which can be caused by the exhaust muffler or by a throttle flap disposed downstream of the exhaust gas recycle line and this pressure is always higher than atmospheric pressure. In this way, a natural pressure gradient is created from exhaust system to suction tube and this pressure gradient causes a controllable exhaust gas recycle flow rate.
According to an advantageous embodiment of the present invention, the device which effects the control of the pressures is a throttle flap and the exhaust gas recycle line terminates in the suction tube downstream of this throttle flap. The throttle flap causes a pressure drop in the suction tube. Instead of placing the throttle flap in the suction tube, the throttle flap may be located in the exhaust line, or some other similar device in the exhaust gas recycle line may serve the same purpose; what is important is that a well adapted exhaust gas recycling is achieved on the basis of the prevailing pressures.
Advantageously, the regulator operates with an air measuring member intended to measure the fresh-air quantity flowing through the suction tube. In order to increase the engine power, it is possible to dispose a gas pump (loader) after the termination of the exhaust gas recycle line in the suction tube. Because an air measuring member is used, there is no requirement to provide a change-pressure dependent control because the aspirated fresh-air quantity is always measured and compared with the injected fuel quantity.
According to the present invention, the control parameter can be either the air quantity or the fuel quantity. In accordance with the first mentioned embodiment of the present invention, the throttle flap is arbitrarily settable, expecially by means of the gas pedal, and the control parameter of the regulator is especially the output signal given by the air measuring member.
In a corresponding embodiment of the present invention, the regulator operates with an electronic control instrument which electronically divides the air-throughput by time and rpm and generates a signal indicative of air-throughput/working cycle which serves as the reference signal for the injection. The injection device can utilize solenoid valves whose opening duration and timing correspond to the reference signal of the injection process. However, the injection device can also be an injection pump with a supply-quantity setting member coupled to the throttle flap, whose setting path is adapted to the reference signal of the injection process.
According to the second mentioned embodiment of the present invention, the quantitative supply of the fuel injection system is arbitrarily changeable and the control parameter of the regulator is the injected quantity. In constrast to the first mentioned embodiment, the regulating characteristics are given here by the regulator of the injection pump. Thus, the entire installation whose purpose is exhaust gas detoxification can be a supplementary mechanism for any injection system and, thus, consideration can be given to any and all customary regulator characteristics of injection systems, such as idling/maximum-rpm regulators, setting regulators with adjustable P-values, etc. In such processes, according to the present invention, the injection quantity and the fresh air quantity can be compared, especially by means of a bridge circuit in the regulator, where this bridge circuit changes the adjustment of the mechanism and therefore the recycle flow rate and also the fresh air flow rate during a deviation from a nominal set-value and until such time as the nominal value is achieved. The bridge circuit can use electrical or hydraulic means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of one embodiment of a fuel injection system for an internal combustion engine according to the present invention, wherein exhaust gas recycling is utilized and including details illustrated partly in cross section of various of the elements which in assembly serve to control the quantity of recycled exhaust gas to thereby reduce the pollution elements of the expelled exhaust gas.
FIGS. 2 and 3 are schematic illustrations like FIG. 1 with the exhaust gas line not shown and with two other embodiments of the assembled elements which control the quantity of the recycled exhaust gas.
FIG. 4 is a schematic illustration of another embodiment of a fuel injection system for an internal combustion engine according to the present invention, wherein exhaust gas recycling is utilized and including details of still another embodiment of the assembled elements which control the quantity of the recycled exhaust gas. The assembled elements in this embodiment including an electrical bridge circuit.
FIG. 5 is a schematic illustration of still another embodiment of a fuel injection system for an internal combustion engine according to the present invention, wherein exhaust gas recycling it utilized with the exhaust gas line not shown and including details of yet another embodiment of the assembled elements which control the quantity of the recycled exhaust gas. The assembled elements in this embodiment include a hydraulic bridge circuit.
FIG. 6 is a detailed view of an alternate servomotor which could be utilized in a system such as that shown in FIG. 5.
FIGS. 7, 8 and 9 are schematic illustrations of further embodiments of the assembled elements which control the quantity of the recycled exhaust gas.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now more specifically to the various figures of the drawing, air is aspirated by an engine 1 through a filter 3, into a suction tube 2 and past an air measuring member 4 and a throttle flap 5. The exhaust gases of the engine 1 flow through an exhaust line 6 in which is disposed a muffler 7. The engine 1, which operates by self-ignition, is supplied through fuel lines 9 by a fuel injection system 8 which injects diesel fuel directly into the engine cylinders or the precombustion chambers of the cylinders. The exhaust line 6 and the suction tube 2 are connected with one another through an exhaust gas recycle line 10 so that, depending on the pressure conditions in the exhaust/suction tube installation, a variable quantity of exhaust gas flows through the recycle line 10 toward the suction side of the installation. The pressure conditions are determined in these embodiments by the throttle flap 5. Depending on the rpm or more precisely depending on how much of a fuel-and-air mixture the engine demands as a result of piston displacement volume (fuel volume aspirated), and depending on which position is taken by the throttle flap 5, the air portion of the fuel volume which cannot flow through the filter 3 because of the position of the throttle flap 5 is derived from the exhaust line 6 and flows through the exhaust gas recycle line 10. As is indicated by the broken line, these pressure conditions can also be caused by a throttle flap 11 in the exhaust line 6 of the exhaust system, which is disposed downstream of the branch point of the exhaust gas recycle line 10 with the exhaust line 6, or else by a control mechanism 12 in the exhaust gas recycle line 10. A natural pressure gradient from the suction side to the exhaust side of the engine 1 is present in any case because, due to the suction within the suction tube 2, there always prevails a certain amount of negative gauge pressure; whereas the expulsion of exhaust gas always causes a certain amount of positive gauge pressure in the exhaust system. Depending on the magnitude of the throttle action of the muffler 7 or the filter 3, this pressure difference is further increased. An even further increase of this pressure difference can be caused by a gas pump or loader 13 disposed in the suction tube 2 downstream of the branch point of the exhaust gas recycle line 10 with the suction tube 2. The important point about the regulator according to the present invention is that just exactly as much fresh air is brought through the filter 3 to the engine 1 as is required by the fuel metered by the injection system 8 so as to achieve favorable combustion. The remaining fuel volume aspirated by the engine consists of the recycled exhaust gas. A cooler 14 can be disposed behind the loader 13 in the suction tube 2 for power increase or NO x reduction.
In the exemplary embodiments shown in FIGS. 1, 2 and 3, the control parameter of the regulator is the fresh air quantity determined by the throttle flap 5 and, to a certain degree, also by the rpm. The throttle flap 5 is coupled to the gas pedal 15 of the vehicle. Of course, the gas pedal 15, instead of actuating the throttle flap 5, may actuate the throttle flap 11 or the control mechanism 12.
FIG. 1 shows an exemplary embodiment in which the air measuring member 4 actuates a fuel metering valve 16 which determines the suction volume of a suction throttle injection pump 17 designed as a distribution pump. The air measuring member 4 includes a plate 20, disposed transversely to the air stream direction in the suction tube 2 and a lever 21. The plate 20 is mounted to the lever 21 which, in turn, engages a metering slide 22 which is located in the fuel flow path of a preliminary fuel supply pump 23. The pressure of the supply pump 23 is determined by a pressure control valve 24. The plate 20 is provided with a constant resetting force which is generated by means of pressure fluid acting against the rear face of the control slide 22. This pressure fluid is also pumped by the pump 23 and is regulated by the pressure control valve 24.
In order to obtain a quantity of metered fuel which corresponds to the position of the control slide 22, but which is independent of the counteracting pressures, a differential pressure valve 25 is placed behind the metering valve 16. The valve 25 includes a membrane 27 which on one side experiences the pressure prevailing ahead of the metering valve 16, and on the other side experiences the pressure prevailing behind the metering valve 16. This latter side is loaded by a spring 28 corresponding to the pressure drop at the metering valve 16.
Connected to a line 29 between the differential pressure valve 25 and an intermittently operating distribution injection pump 17 is a storage container 30. The container 30 accepts the metered fuel quantity on each occasion when the injection pump 17 closes its suction aperture 31, and then delivers it into a pump operating chamber 32 of the injection pump 17 after the aperture 31 is opened. In this way, an integrating effect is achieved.
For regulating the maximum rpm or for safety shut-off regulation, use is made of a centrifugal force regulator 33 controlling a valve 34 in the suction line 29. Hence, in this fuel injection system, the suction throttle flap 5 and the engine rpm determine what particular air quantity passes the air measuring member 4, corresponding to which a particular fuel quantity is metered out by the fuel metering system 16. This fuel quantity determines the filling quantity of the fuel injection pump 17. Thus, the injected fuel quantity can always be adapted to the fresh air quantity in order to obtain favorable combustion.
In the exemplary embodiment shown in FIG. 2, the air measuring member 4' is a baffle plate 35 whose shaft 36 is coupled to a sliding contact 37 of a potentiometer 38 supplied with constant DC potential. The potentiometer 38 has an exponentially increasing characteristic and hence delivers a control voltage which is at least approximately linear with respect to the air throughput and this control voltage is fed as a control parameter to an electronic control instrument 39. The electronic control instrument 39 controls four electromagnetically actuatable injection valves 40, of which each valve injects into one engine cylinder or one corresponding precombustion chamber associated with it. The magnetic valves 40 can be pump nozzles or they can also be high pressure injection valves. Control instrument 39, as is usual, contains a monostable multivibrator which is triggered by a signal source (not shown) coupled to the crankshaft of the engine and which determines the opening duration and, hence, the fuel quantity emerging from the injection valves. The adaption of the particular injection quantity is achieved by known means not shown. The injection valves 40 are supplied with fuel by a fuel pump 41 with the inlet pressure being controllable by a pressure control valve 42.
In the exemplary shown in FIG. 3, the signal derived from the air measuring member 4', which has the same configuration in this example as it did in the exemplary embodiment of FIG. 2, is electronically divided by a signal derived due to engine rpm in order to achieve a new signal measuring the quantity: air throughout/working cycle. The fuel injection mechanism, in this case, includes a serial injection pump whose shaft rotates with engine rpm and is equipped with a signal generator 45, by means of which the rpm information is delivered to the control instrument 39. The actual value of the injection quantity is indicated by a potentiometer 46 whose slide contact 48 is coupled with a control rod 47. The potentiometer 46 has a linear characteristic so that the voltage delivered to the control instrument 39 is a linear function of the injected fuel quantity provided that the path of the control rod 47 has a linear relationship to the metered fuel quantity. The shaft 49 of the throttle flap 5 is connected to an eccentric point 50 of an adjustment lever 51 of the control rod 47 so that a movement of the throttle flap 5 by the gas pedal 15 results in a displacement of the control rod 47. This coarse adjustment of the injection quantity, corresponding to the actual value, is corrected by a magnetic servomotor 52 toward the nominal set value as determined by the electronic control instrument 39 from the electronically derived air throughput/working cycle quotient and from the position of the control rod 47 wherein these two values agree.
For this purpose it is possible, for example, to use a bridge circuit with comparison resistors within the electronic control instrument and the magnetic servo-motor 52 being placed in a diagonal branch of the bridge. The safety and maximum rpm shut-off regulation occurs, in this injection pump as well as in the others, as usual, by means of a centrifugal force governor 53.
In the two further exemplary embodiments shown in FIGS. 4, 5 and 6, the control parameter for the regulator is the injected fuel quantity. As is usual in diesel-type internal combustion engines, the gas pedal 15 of the vehicle determines the fuel injection quantity supplied by the injection pump 55. Customarily, the injection pump 55 operates with the hydraulic or mechanical regulator in which the injected quantity is regulated depending either on rpm or load. The injection pump 55 is usually driven directly by the engine at a speed corresponding to engine rpm. Thus, an installation of this type can be adpated to any existing diesel fuel injection system with the only requirement being that an exhaust gas recycle line 10, as well as means for controlling the pressures in the suction and exhaust systems of the internal combustion engine such as, for example, the throttle flap 5, be provided. In addition, an air measuring device 4" is needed. Because it is intended that the injected fuel quantity be the control parameter, and because the quantity aspirated by the fuel injection pump 55 corresponds to the injected fuel quantity, it is sufficient to measure the quantity aspirated by the fuel injection pump 55 for measuring the actual value of the injection quantity.
In the exemplary embodiment shown in FIG. 4, this fuel quantity is measured by a heated wire 56, disposed in the pressure line 55' of the pump 55, and acting as a variable resistance in an electrical bridge circuit 57. Another heated wire 58 is disposed in a further branch of the bridge 57 and acts as a variable resistance measuring the air quantity in the suction tube 2. The remaining two branches of the bridge 57 contain fixed resistance 59 and 60. System line voltage is connected across one diagonal branch 61 of the bridge 57 whereas the second diagonal branch 62 of the bridge 57 carries the differential voltage which is amplified by an operational amplifier 63 and delivered to a magnetic setting mechanism 64 which sets the throttle flap 5 until the controlled fresh-air quantity passing the heated wire 58 causes a change of resistance whose consequence is that the voltage occurring across the diagonal branch 62 becomes zero.
In the exemplary embodiment shown in FIG. 5, use is made of a hydraulic circuit. In this case, the fuel quantity flowing to the fuel injection pump 55 is measured by a setting piston 65 which includes a control edge 66 which in turn controls a throttle slit 67 so that the path of the piston 65 is a linear function of the cross section of the throttle 67. One diagonal branch of this hydraulic bridge is formed by a fuel supply system with a supply pump 68. The suction side of the pump 68 is connected through a line 69 to a connecting point 70 of this diagonal branch and the pressure side of the pump 68 is connected through a line 71 with the other connecting point 72 of this diagonal branch. On the one hand, fuel flows from the connecting point 72 through the throttle slit 67 and a line 74 to the injection pump 55; while on the other hand it flows from the connecting point 72 through the throttle slit 67 and a branch 73 in which is disposed the fuel measuring mechanism including the piston 65, and further to a connecting point 75 of the bridge to which is also connected the second diagonal branch 76. Disposed within the branch lying between the connecting points 70 and 75 is a throttle valve 77. The throttle valve 77 has a throttle slide 78 which is actuated by a lever 79 having a free end lying within a suction tube to which a plate 80 is fastened to lie transverse to the stream direction, and this plate extends into a funnel portion of the suction tube 2, just as in the first exemplary embodiment. To this free end a plate 80 is attached in such a way that the path of the plate 80 corresponds to the air quantity flowing through the suction tube 2. The slide 78 controls a slit 81 in such a way that the path of the slide 78 corresponds to the open cross section of the valve 77. The resetting force for the slide 78 is obtained from pressure fluid which is supplied by the pump 68 through a channel 82 to the rear side of the slide 78. Lines 84 and 85, which respectively contain fixed throttles 86 and 87, are provided between the connecting points 70 and 72 and a fourth connecting point 83, to which the diagonal branch 76 is also connected. As soon as a differential pressure occurs between the connecting points 75 and 83 of the diagonal branch 76 (of the bridge as such), a piston 90 belonging to a hydraulic servo-motor 90' is displaced and this piston is connected with the throttle flap 5 by link means 91. Corresponding to a particular suction quantity of the injection pump 55 the piston 90, an hence the throttle flap 5, are displaced until such time as the aspirated fresh-air quantity corresponds to a nominal set value and this occurs when no pressure difference is any longer present between the connecting points 75 and 83 of the hydraulic bridge circuit.
The hydraulic servo-motor 99' shown in FIG. 6 contains a control slide 95, whose two setting surfaces respectively experience the pressures prevailing at the connecting points 75 and 83. The control slide 95 has annular grooves 96 and 97 controlling a bore 98 leading to the servo-motor 99' which, in turn, is connected by link means 91 with the throttle flap 5. The annular groove 96 communicates with the pressure line 71 of supply pump 68 and the annular groove 97 communicates with a pressure-relieved line 100.
As was the case in the embodiment shown in FIGS. 4, 5, and 6, the control parameter for the regulator in the exemplary embodiment shown in FIGS. 7, 8 and 9, is the fuel injection quantity arbitrarily settable by the injection pump. As was the case in the exemplary embodiment of FIG. 5, the air measuring member 4 has the form of a lever 79 to whose free end is fastened a plate 80, transversely to the air stream direction. The member 4 actuates a throttle valve 77. The control valve slide 78 of the throttle valve 77 determines the opening of a control slit 81 so that the path of the slide 78 corresponds to the open cross section of the valve 77. Fuel under constant pressure is carried from the supply pump 68 through a line 102 to the throttle valve 77, and after flowing through the control slit 81, it is further carried through a line 103 to the injection pump 55. In a known manner, a well-defined pressure drop occurs in the control slit 81 corresponding to the amount of fuel flowing through the slit 81. This passing fuel quantity is determined by the driver operating the gas pedal 15, and hence determining the injection quantity of the pump 55. The pressure drop determined by the cross-sectional area of the control slit 81 is compared with the reference pressure in order to determine whether the nominal set value of the fresh-air quantity corresponds to the injected fuel quantity. The reference pressure is created in a line 104 which is connected to a line 102 by a line 105. The line 105 carries throttle 106 for pressure decoupling. Branching off from the line 104 is a line 107 leading back to the reservoir and also containing a throttle 108 intended to preserve a desired pressure. Depending on the difference between the pressure in the line 103 and the line 104, the servo-motor, including the piston 90, in the embodiments of FIGS. 7 and 8 is actuated and sets the throttle flap 5 by means of the links 91 until the difference in the pressures in the lines 103 and 104 has reached a desired value. According to the embodiment of FIG. 7, this purpose is achieved by a differential pressure indicator 109 operating with a membrane 110 whose one side is actuated by the pressure in the line 103 and whose other side is actuated by the pressure in the line 104. On each side of the membrane 110, which is preferably metallic, are located electrodes 111 and 112 which, depending on the pressure difference, can make contact with the membrane. Only when the pressure is equal is there no contact between either electrode and the membrane; i.e., when the pressures are equal in lines 103 and 104, the air quantity does correspond to the injected fuel quantity. Electrodes 111 and 112 control magnetic valves 113 and 114 which in turn control the quantity of fuel flowing to the servo-motor 90' and hence also the control pressure in the servo-motor 90'. In this case, too, the control fluid is fuel admitted through a line 115 which divides into lines 116 and in each of which there is disposed a throttle 117. Branching off downstream of the throttles are lines 118 and 119 which lead to the servo-motor on either side of the setting piston 90. The valves 113 and 114 are disposed in the further extent of the line 116. Downstream of the valves 113 and 114, the line 116 is carried back to the fuel container. Thus, as soon as valve 113 or 114 opens, the corresponding branch of the line 116 is opened so that fuel from the servo-motor can flow out of the line 118 or the line 119 without pressure; or on the contrary, as soon as one of these valves is closed, a pressure may build up at the corresponding side of the servo-motor. The resetting force of the air measuring member 4 is generated by a pressure fluid acting on the front end of the throttle slide 78 and is provided from line 102 through a line 120. Disposed in this line 120 is a decoupling throttle 121 whose purpose is to achieve as constant a resetting pressure as possible which is also independent of the pressure fluctuations in the line 102 caused by the changing control slit 81. Branching off from the line 120 is a line 122, terminating into line 116 downstream of the magnetic valve 114. Disposed in the line 122 is variable throttle 123 which permits setting the reset force, i.e. the pressure in the lne 120.
The installations described in FIG. 7 functions as follows:
Beginning with a condition of equilibrium prevailing in the regulator, i.e. equal pressures in the lines 103 and 104, the application of an open throttle results in a larger fuel supply quantity from the injection pump 55 and the equilibrium is disturbed. Due to the effect of the suction of the injection pump, the pressure in the line 103 decreases and the pressure gradient in the control slit 81 is correspondingly increased. Due to the pressure decrease in the line 103, the membrane 110 is displaced toward the electrode 112 opening the normally closed valve 114. Opening of the valve 114 causes a pressure decrease in the line 119 and a corresponding downward displacement of the servo-motor causes the throttle flap 5 to open up the suction tube 2. The opening of the suction tube 2 causes an increase of the fresh-air flow passing the plate 80 as compared with the exhaust gas flow aspirated through the recycle line 10. Corresponding to this increase of the fresh-air flow, the slide 78 of the throttle valve 77 is displaced and the control slit 81 is further opened, which, in turn, results in an increase of pressure in the line 103. As soon as pressure equilibrium again prevails in the lines 103 and 104, the membrane 110 is released from the electrode 112 and assumes its central position. Consequently, the magnetic valve 114 closes and the servo-motor 90' remains in the corresponding control position. When the injection quantity is subsequently reduced again, the pressure in the line 103 rises, due to the corresponding additional supply of system pressure in the line 102, and the membrane 110 is displaced toward electrode 111. This, in turn, has the consequence that the magnetic valve 113 is opened and the servo-motor 90' again closes the throttle flap 5 further until a pressure equilibrium, corresponding to the injected fuel quantity, prevails in the lines 103 and 104.
In the exemplary embodiment shown in FIG. 8, purely hydraulic means are used instead of the electrical means of FIG. 7. Three equal pressure valves are used to displace the servo-motor 90' until the pressure in the lines 103 and 104 is the same. Otherwise this regulator functions in the same way as that in FIG. 7 and, for this reason, individual and equivalent means are not shown. Branching off from the line 102 is a line 125 which carries fuel under pressure to lines 126 and 127. Disposed within the lines 126 and 127 are throttles 124 which serve for a certain degree of decoupling from the system pressure in the line 102. Downstream of these throttles there are disposed in lines 126 and 127 equal pressure valves 128 and 129 through which and depending on the difference in the pressures in the lines 103 and 104, a portion of the fuel may flow to the lines 130 and from there into the return line 122 and ultimately into the fuel reservoir. For this purpose the valves 128 and 129 are equipped with a dividing membrane 131. One side of the membrane 131 in the valve 129 experiences the pressures in the line 104 which is transmitted through a line 132, whereas in the valve 128, one side of the membrane 131 experiences the pressure in the line 103 transmitted through a line 133. The other sides of the membranes 131 are actuated by the pressure prevailing downstream of the throttles 124 in the lines 126 and 127. Accordingly, when the pressure in the lines 132 and 133 increases, less fuel flows off through the lines 130 and vice versa. The pressure in the lines 126 and 127 is changed accordingly. This pressure, in turn, acts upon a membrane 135 of an analog control regulating valve 136. The membrane 135 controls the ends of two lines 137 and 138 which lead to eiher side of a setting piston 90 in the servo-motor 90' and then back to the return line 122. Downstream of the servo-motor 90', the lines 137 and 138 contain build-up throttles 140.
The principle of operation of this exemplary embodiment is exactly the same as that of FIG. 7. As soon as a pressure difference occurs between the lines 103 and 104, the pressure in the valves 128 and 129 above membrane 131 is correspondingly changed. This, in turn, results in a differential flow-off of fuel through the lines 130. The differential flow-off, in turn, results in a differential pressure-activation of the membrane 135 in the regulating valve 136 which causes it to be displaced either toward the line 137 or the line 138. Corresponding to the resulting greater throttling, this pressure difference is transmitted to the servo-motor 90' which results in the desired setting of the throttle flap 5.
In the exemplary embodiment shown in FIG. 9, the pressure of the supply pump 68 is transmitted through a line 142 directly to a differential pressure valve 143. This differential pressure valve 143 functions by means of a membrane 144 whose upper surface experiences pressure prevailing in the line 103 as well as the force of a spring 145 causing the differential pressure. The lower side of the membrane 144 controls the terminating aperture of a line 146 and experiences pump pressure admitted to it through the line 142. The line 146, in turn, leads to the servo motor 147 whose piston 147' is slidable against the force of a spring 148. Located in the piston 147' is a throttle channel 149 through which fuel can continuously flow into a return line 150 which contains a pressurizing throttle 151 for additional adjustment. Thus, as soon as the pressure in the line 103 decreased due to an increasing injection quantity, the membrane 144 is displaced upwardly against the force of the spring 145 and against the fluid pressure prevailing in the line 103 and thus opens the line 146 further. As a result, the piston 147' is displaced and opens the throttle flap 5 in the desired manner until, because of the enlargement of the throttle slit 81 in the line 103, the previous pressure prevails again.
In contrast to the other embodiments, the throttle flap 5 controls the terminating aperture of the exhaust gas recycle line 10. It should be noted, however, that this configuration of the recycle line 10 is possible in the other embodiments as well. For the purpose of controlling the terminating aperture of the recycle line 10, use is made of the section 153 of the throttle flap 5 which operates downsteam of the axis 154 in the suction tube 2. This disposition has the advantage that the unimpeded motion of the throttle flap 5 is not substantially deteriorated by contamination and dirt. The closure of the exhaust gas recycle line 10 during full load operation, i.e. with a fully opened throttle flap 5, can be of importance when the air quantity measuring member 4 operates with a relatively large pressure drop in the suction tube 2 or when high gauge pressure prevails in the exhaust system during full load operation so that exhaust gas could be unintentionally aspirated through the exhaust gas recycle line 10.
Regulating systems corresponding to FIGS. 1 and 9 can also be used in externally ignited engines (spark plug ignited) using fuel injection.
They can especially be used also in a directly injected stratified charge engine which requires intermittent, timed injection just as does a self-igniting internal combustion engine.
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What follows is a description of a fuel injection system for an internal combustion engine which employs exhaust gas recycling. The engine has a suction tube leading to the engine and an exhaust pipe leading from the engine, while the system includes a recycle line connecting both the exhaust pipe and the suction tube, and a control mechanism. The control mechanism can be located either in the suction tube, the exhaust line or the recycle line and controls the pressure therein in order to control the recycled exhaust gas flow rate. The system further has a regulating structure which regulates the quantity of the injected fuel in conjunction with the control mechanism.
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FIELD OF THE INVENTION
The present invention relates to an intake control system for an internal combustion engine, with a particular utility in a two-cycle multicylinder engine.
BACKGROUND OF THE INVENTION
In addition to the butterfly valve system widely used in carburators, intake control systems are also known which include a translationally displaceable throttle plate. However, known systems of the latter type are of delicate and complicated design and are difficult to service.
SUMMARY OF THE INVENTION
The system of the invention can operate either with a carburator intake to control the volume of air-fuel mixture entering the cylinders, or, preferably, with fuel injection to control the volume of air admitted, for example, into the sealed crankcase of a two-cycle engine.
According to the invention, the intake control system for an internal combustion engine, in particular a two-cycle multicylinder engine, which includes a movable throttle plate designed to cause the passage cross-section of the engine cylinders' intake manifolds to vary, is characterized by including the following features: a substantially rigid plate pierced with orifices designed to be connected respectively with each of the intakes corresponding to the various engine cylinders; a movable blade, with a number of apertures equal to that of the orifices in the plate, the spacing between these apertures being equal to the spacing between these orifices; control means and guiding means of the blade, said means designed for the blade to move parallel to the plate, and to pass from a running position in which the apertures in the blade are substantially opposite the orifices in the plate to an idle position wherein the orifices of the plate (or at least a majority) are obturated by the blade; and elastic elements which are arranged to apply, in a gastight manner, the solid parts of the blade to the solid parts of the plate.
According to an important characteristic of the invention, the thickness of the blade and the mechanical characteristics of the material composing it are chosen such that, under the action of the elastic elements, the blade takes on the shape of the surface of the plate to which it is applied and also resists the force due to the negative pressure prevailing in the intake manifold during operation.
Thus, due to a judicious choice of the flexibility of the movable blade, problems of tightness between the movable blade and the plate are resolved very simply, without entailing costly machining of the corresponding faces of the plate and the blade. Moreover, this system has great operating reliability as the movable blade is capable of taking on the shape of the corresponding face of the plate if the latter bends slightly due to forces exerted during assembly or operation.
According to a preferred embodiment of the invention, the movable blade is mounted in a substantially dust-sealed box one side of which is constituted by the plate and the other side by a lid with a peripheral flange applied to the plate. Thus, only one face of this flange need be machined.
The elastic components can be constituted by a leaf spring or by a series of coil springs. Moreover, the apertures in the blade each communicate with a slot of small cross section which is opposite one orifice of the plate in the idle position such as to permit fine adjustment of the engine idle speed.
According to an advantageous embodiment of the invention, the control means of the movable blade includes a manual activating means and an elastic return means arranged such that the activating and return forces are co-linear and substantially parallel to the blade such as to avoid any flexional torque on the blade which could cause the blade to bend and thus destroy its tightness.
It is accordingly an object of the present invention to overcome the defects of the prior art as mentioned above.
Another object of the present invention is to produce an intake control system with a displaceable throttle plate.
A further object of the present invention is to produce an intake control system which is both rugged and inexpensive.
Still another object of the present invention is to produce an intake control system in which a movable blade is capable of taking on the shape of a corresponding face of the plate.
Other characteristics and advantages of the invention will become apparent from the detailed description hereinbelow.
BRIEF DESCRIPTION OF THE DRAWING
A preferred embodiment of the invention is shown in the attached drawings provided as non-limitative examples.
FIG. 1 is a schematic perspective view showing a control system according to the invention cooperating with a multi-cylinder engine.
FIG. 2A is a lengthwise cross sectional view taken along the line II--II of FIG. 3 of the control system shown in FIG. 1 with the movable blade in the idle position.
FIG. 2B is a lengthwise cross sectional view of a control system similar to that of FIG. 2A according to a variant of the invention.
FIG. 3A is a cross sectional view along line III--III of FIG. 2A.
FIG. 3B is a cross sectional view along line III--III of FIG. 2B.
FIG. 4 is a transverse cross sectional view along line IV--IV of FIG. 2A.
FIG. 5A is an elevational view of a leaf spring which is part of the system of FIGS. 2A and 4.
FIG. 5B is an elevational view of a leaf spring which is part of the system of FIG. 2B.
FIG. 6 is a view similar to that of FIG. 4 showing an alternative embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 schematically shows an intake control system 1 according to the invention for a multicylinder internal combustion engine which uses, for example a two-cycle engine.
In the embodiment to be described, the engine is assumed to be supplied by a fuel injection system such that system 1 is designed to control the volume of air admitted into the engine.
This system is connected on one side to an assembly of silencers and air filters 2. On the other side it is connected by flexible pipes 3 to the air intakes 4 each corresponding to each of cylinders 5.
System 1 includes a substantially dust-tight casing composed of a plate 6 and a lid 7 (FIGS. 2A and 3A; FIGS. 2B and 3B). Plate 6 has orifices 8 designed to be connected to intakes 4 by pipes 3 in a number equal to the number of cylinders 5. The inside face line of the plate is finished with fairly wide tolerances as to planes, while the rest of the plate can be cast.
Lid 7 has a peripheral flange 10, the face of which is applied to the plate, is finished while the rest of the lid can also be cast. The lid has orifices 11 disposed opposite orifices 8 of the plate and designed to be connected to the silencers and air filter assembly 2. Plate 6 and lid 7 are attached to each other by bolts (not shown) which, for example, pass through holes 12.
Inside this casing is disposed a movable throttle plate constituted by flexible blade 13 which is mounted such as to be translationally displaceable in a parallel plane to the inside face 9 of plate 6. In the case where intake pipes 3 are arranged in a line, as shown in FIG. 1, the translational movement of blade 13 is rectilinear but it is understood that the invention can equally well apply to other arrangements by providing a curvilinear translational movement of blade 13.
Blade 13 has openings 14 which are straight-edged in the embodiment shown. In these openings are engaged guide pins 15 supported by the plate and the lid.
Apertures 16 corresponding to the same number as the orifices of the plate and of the lid and having the same spacing as the orifices, are constructed in blade 13. These apertures have a generally circular principal part of diameter d which is less than half the distance between the centers of two adjacent orifices. In addition, each aperture according to the first variant of the present invention is extended by a slot 17 (FIG. 2A) of small cross sectional area disposed along the axis of the blade 13, the function of which will be explained subsequently.
It will be noted that the portions of blade 13 in which apertures 16 are made of a length slightly greater than (2) (d). These portions are separated by shorter portions 18 in which openings 14 are made in order to increase the flexibility of blade 13, in the direction perpendicular to the plane of FIG. 2A and FIG. 2B. The face of blade 13 which is applied to plate 6 is polished and can advantageously be covered with an anti-friction coating to reduce friction between the plate and the blade.
Between blade 13 and lid 7 is arranged a leaf spring 19 (FIG. 3A and 5A; FIGS. 3B and 5B) of undulated shape which can bear both on lid 7 and on blade 13 to apply the latter to plate 6. It will be seen from FIG. 5A and 5B that spring 19 is recessed such that its bearing zones 20 on blade 13 are situated on both sides of apertures 16 of the blade, in the vicinity of the edges of the latter, such as to maintain a free space in the zone swept by the apertures when the blade moves.
At its median part, movable blade 13 has an actuating tab 21 which projects outside the casing through a slot 22 made in the flange of lid 7 (FIGS. 2A, 2B and 4). This tab is fixed by a rivet 23 to a slide 24 which has two half-shells, gripping tab 21 between them. Slide 24 has a slot 25 in which is engaged a lead button 26 at the end of a control cable 27. A return coil spring 28 disposed coaxially to cable 27 bears on one side on slide 24 and on the other side on a boss 29 of lid 7. The assembly of these control elements is protected by a hood 37.
Another boss 30 is arranged on the other side of slide 24 with respect to boss 29 and has a tapped sheath 31 in which is engaged an idle adjustment screw 32 fitted with a return spring 33. The end of this screw serves as an adjustable stop for slide 24 at one end of its stroke.
Screw 32 can, as shown in FIG. 2A and in FIG. 2B, be hollow to allow for passage of a second control cable 34 shown in dots and dashes which is attached to slide 24 by a lead button 35 engaged in a second slot 36. In the case of control which is positive in both directions, a return spring 38 acts on this second cable.
FIGS. 2A and 3A represent movable blade 13 in the idle position in which slide 24 bears on the end of screw 32. In this position, most of the orifices 8 of the plate are blocked by blade 13 except for a small portion which is opposite slot 17 (FIG. 2A). By turning screw 32 on can vary the surface of the parts so cleared and it will be understood that the small cross sectional area of slots 17 permits fine adjustment of this surface and thus allows the deceleration of the speed of the engine.
The thickness of movable blade 13 and the mechanical characteristics of the material composing it are chosen such that the blade perfectly matches the shape of face 9 of plate 6 on which it is applied by the action of spring 19 and such that it does not collapse when subjected to the forces due to the low pressure prevailing in engine intake manifold 3. It will be understood, under these conditions, that outside slots 17, (FIG. 2A) blade 13 and face 9 of the plate form an airtight connection even if the plate has become slightly bent during assembly or operation. It will also be understood that to obtain this tightness it is not necessary to impose very narrow tolerances as to the planeness of face 9 of the plate. This is due to the fact that the blade acted upon in the direction of this face of the plate by spring 19 is applied against this face by the differential pressure existing between its two sides in the same manner as a valve flap is applied to its seat. It is this action of differential pressure distributed over the entire surface of the blade which, combined with its flexibility, compels the blade to match the shape of face 9 of the plate, and thus enables perfect tightness to be made with a low plate-machining cost.
When cable 27 and/or secondary control cable 34 is acted upon to increase the engine speed, slide 24 moves in the direction of arrow f by compressing spring 28. Apertures 16 are progressively superimposed on orifices 8 and 11 of the plate and lid, thus increasing the air passage cross section.
It will be noted that the forces acting on the cables and on return spring 28 are co-linear and are situated in the plane of blade 13. Accordingly, the latter is subjected to no flexional torque when moving, which would tend to deform it or separate it from the base of the plate. The resultant of these forces acting on the blade can advantageously be reduced by anti-friction coating of the movable blade.
Instead of providing slots 17 (FIG. 2A) for idling the engine, one may, according to the second variant shown in FIGS. 2B, 3B and 5B, pierce in plate 6, channels 39 which emerge opposite apertures 16 of the movable blade when the latter is in idle position. These channels in the second variant are connected outside the casing by ducts 40 to other channels 41 pierced in the wall of orifices 8 of the blade. This enables the idle to be adjusted independently for each cylinder.
FIG. 6 shows an alternative embodiment in which the single-leaf spring 19 is replaced by a series of coil springs 42 which, in the region of each of orifices 8 of the plate, applies movable blade 13 to plate 6, bearing on shoulder 43 of lid 7.
The invention is, of course, not limited to the embodiment described hereinabove and many variations of design available to the engineer may be made thereto without departing from the scope of the invention. Thus, displacement of the movable blade is not necessarily a translational displacement provided that the blade moves parallel to the plate.
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An intake system for an internal combustion engine has been developed to include a translationally movable throttle to cause cross-sectional passage of the intake manifold of the engine cylinders to vary. This throttle utilizes a substantially rigid plate which is pierced with orifices adapted to be connected with each of the intakes corresponding to the various engine cylinders. A movable blade is provided with apertures corresponding in number and spacing to the orifices which contacts with a control and guide means so that the blade is allowed to move parallel to the plate from a running position in which the apertures of the blade are substantially opposite the orifices of the plate to an idle position in which at least the majority of the orifices of the plate are obturated by the blades.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to novel α-hydroxylated β-unsaturated carboxylic acids. In more detail, it relates to novel α-hydroxy-acids of the general formula: ##STR2## The present invention also relates to the process of preparation and to the use of α-hydroxy-acids of formula (I). In particular, these novel products represent intermediates which provide access, by oxidative decarboxylation, to homologous lower aldehydes (prenal, citral, etc.). Such aldehydes in turn allow access to vitamin A or can also be used for their aroma properties.
It is known from French Patent 1,554,805 to prepare α-ethylenic carbonyl compounds by isomerization of α-acetylenic alcohols. This isomerization takes place by heating the alcohol, optionally in a solvent, in the presence of small quantities of a catalyst based on a metal belonging to groups 3b to 7b of the periodic table of the elements Advantageously, this isomerization takes place in the liquid phase, and the catalyst is an inorganic or organic derivative of a metal selected from the group comprising vanadium, niobium, molybdenum, tungsten and rhenium.
It is also known from U.S. Pat. No. 3,057,888 to prepare unsaturated aldehydes from esters of 1,1-disubstituted propargyl alcohol by heating in an acidic medium in the presence of a catalyst containing a metal belonging to group lb of the periodic table of the elements.
Moreover, it is known from U.S. Pat. Nos. 2,524,865 and 2,524,866 to prepare ethylenic aldehydes by treating alkynols in the vapour phase under the action of various acidic catalysts. However, this process gives only a ternary mixture of an ethylenic aldehyde, ketone and hydrocarbon.
The present invention describes a novel access route to these aldehydes, and in particular to prenal and citral, from esters of β,γ-unsaturated carboxylic acids. In addition, this route gives very good yields and has made it possible to display and to isolate novel α-hydroxylated β-unsaturated carboxylic acid compounds as intermediates.
SUMMARY OF THE INVENTION
One object of the present invention thus relates to novel compounds of the general formula (I): ##STR3## in which n can be 0, 1, 2 or 3. PG,4
In particular, the invention relates to compounds of the general formula (I) in which n=0, that is to say 2-hydroxy-4-methyl-pent-3-enoic acid, and n=1, that is to say 2-hydroxy-4,8-dimethyl-nona-3,7-dienoic acid.
Another object of the present invention concerns a preparation process for these compounds of general formula (I) from esters of β,γ-unsaturated carboxylic acids of the general formula (II), set forth below.
The first and second objects of the invention are provided by a process for the preparation of a compound of the general formula (I) comprising:
a first stage wherein an ester of the general formula (II): ##STR4## in which R is an alkyl group preferably having 1 to 4 carbon atoms and n is preferably equal to 0, 1, 2 or 3, is saponified to form the corresponding acid,
a second stage wherein the dianion of the acid thus obtained is prepared by the action of a base preferably selected from alkali metal hydrides, alkaline earth metal hydrides, alkali metal amides and organometallic alkyls, in an organic solvent, and
a third stage wherein the dianion is oxygenated to form the acid of the formula (I).
A third object of the present invention relates to the use of these novel compounds for the preparation of homologous lower aldehydes by oxidative decarboxylation by means of an oxidizing agent.
The third object of this invention is accomplished by a method for the preparation of homologous lower aldehydes of the compound of the general formula (I) wherein the compound undergoes oxidative decarboxylation by means of an oxidizing agent.
DETAILED DESCRIPTION
In the process of this invention, the first stage involves the following reaction: saponification of the ester (II) to produce the acid of the general formula (III) ##STR5##
In a particular embodiment of the invention, R which can be an alkyl group having preferably 1 to 4 carbon atoms is a methyl group, and n, which can be 0, 1, 2 or 3, is equal to 0 (methyl 4-methyl-pent-3-enoate) or equal to 1 (methyl 4,8-dimethyl-nona-3,7-dienoate).
The saponification reaction can be carried out by means of a strong base of the M--OH type, in which M is preferably an alkali metal or a quaternary ammonium group, in an organic solvent. In particular, this can be effected in water-miscible solvents, including alcohols such as methanol, ethanol, isopropanol etc. In a preferred embodiment of the invention, methanolic sodium hydroxide can be used.
The reaction temperature is preferably between ambient temperature and the reflux temperature of the mixture.
The esters of the general formula (II) can be prepared from isoprene, or a higher homologue, according to the process described in French Patent FR 81 01,205, which is incorporated specifically by reference herein. The reaction can be conducted as follows: ##STR6##
This carbonylation reaction can be effected by means of carbon monoxide in the presence of an alcohol, R--OH, corresponding to the desired ester and preferably in the presence of at least one of the following: a hydrohalic acid (in particular hydrochloric acid or hydrobromic acid) and a palladium catalyst (palladium metal, palladium oxide, a palladium salt or complex whose anion coordinated with the palladium cation is a "hard" or "intermediate" base) and more preferably in the presence of a hydrohalic acid, a palladium catalyst and a quaternary onium salt of a group Vb element selected from nitrogen, phosphorus and arsenic, at a temperature ranging from about 50 to about 150° C. and under a carbon monoxide pressure ranging from about 50 to about 300 bars. Under these conditions, the ester can be obtained in very good yields.
With respect to the second stage of the present process, the preparation of the dianion of the acid (III), the following procedure can be employed:
The dianion can be obtained by the action of a base such as the alkali or alkaline earth metal hydrides or amides, or the organometallic alkyls, deposited or grafted on a support if desired, in an organic solvent. According to the present invention, the alkali metal amide can be selected from lithium diisopropylamide (LDA) which can be prepared "in situ" by the action of butyllithium on diisopropylamine, sodium tert.-butylate or also sodium amide.
The hydrides which can be used in this reaction are preferably hydrides of sodium, potassium or calcium. With respect to the organometallic alkyls, organolithium compounds, organomagnesium compounds and the sodium or potassium alkyls can be used. Specifically, butyllithium is most preferred.
In a preferred embodiment of the invention, LDA is used as the base.
In the case of heterogeneous bases, oxide-type supports, for example, can be used, preferably aluminas. In this connection, potassium tert.butylate and potassium fluoride on alumina may be mentioned as heterogeneous bases.
With respect to the organic solvent, all ether-type solvents can be suitable for this reaction. Preferably, tetrahydrofuran, diisopropyl ether, methyl tert.-butyl ether or paradioxane is used. In a most preferred embodiment, tetrahydrofuran is used.
Finally, the reaction of forming the dianion is advantageously carried out at low temperature and preferably at temperatures ranging from about -20° C. to about +20° C., more preferably from about -10° C. to about +10° C. In certain cases, the temperature can temporarily be raised at the end of the reaction to shift the equilibrium of the reaction as far as possible towards formation of the dianion. This thermal finishing treatment preferably takes place at temperatures ranging from 20° C. to 50° C., and more preferably from 30° C. to 40° C.
The third stage of the present process, which concerns the oxygenation of the dianion, is preferably carried out as follows.
The oxygenation of the dianion to produce the α-hydroxy-acid of the general formula (I) is effected by means of oxygen or air, optionally enriched with oxygen, and more preferably by air. It can be carried out by allowing the oxygen or air to come into contact with a stirred solution of the dianion, or by sweeping across the surface of the said solution. In another embodiment, the oxygenation can be achieved by means of pressurized air. Advantageously, this reaction is preferably carried out after the temperature is close to ambient temperature.
When the process which is the subject of the invention is carried out, secondary products can form in which the oxygenation has not taken place in the α-position of the acid. However, these products can arise in very subordinate amounts and, because of their low degree of crystallization, they can be eliminated by filtration after the crystallization of the main products.
The third object of the present invention relates to the use of these novel compounds for the preparation of homologous lower aldehydes by oxidative decarboxylation by means of an oxidizing agent, as follows: ##STR7##
This reaction can be carried out by means of an oxidizing agent such as an acetate of one or more metals selected from cobalt, manganese, lead, silver or the copper-lead couple, and preferably selected from cobalt and lead. In particular, lead tetraacetate gives very good results.
It is equally possible to effect the oxidative decarboxylation indirectly by the free-radical techniques described by Maumy et al. (Tetrahedron Letters, 1983, 3819), specifically incorporated by reference herein. In particular, metals, especially those such as Cu 2 O, can be used in a solvent which stabilizes copper (I), such as acetonitrile, at atmospheric pressure.
Other subjects and advantages of the present invention will be appreciated by reading the examples which follow and which are to be considered as illustrate and not limit the invention.
EXAMPLE 1Synthesis of 4-methyl-pent-3-enoic acid by saponification of methyl 4-methyl-pent-3-enoate
12.8 g (100 mmol) of the ester methyl 4-methyl-pent-3-enoate are used, which are diluted with 50 ml of methanol. 15 ml of 30% sodium hydroxide solution (112 mmol) are added dropwise. The solution obtained is heated under reflux for 3 hours with stirring. The solvent is then evaporated to dryness and the remaining carboxylate is treated with 15 ml of concentrated HCl. The acid is then extracted with ether and the extract is dried over Na 2 SO 4 . The ether is then evaporated and the last traces of water are eliminated under a vane-pump vacuum. Under these conditions, the conversion rate of the ester is 100% and the yield is 92%.
EXAMPLE 2 Preparation of 2-hydroxy-4-methyl-pent-3-enoic acid
4 g of diisopropylamine in solution in 60 ml of anhydrous tetrahydrofuran are introduced under an argon atmosphere into a three-necked 250 ml reactor fitted with a central stirrer, a condenser, a 50 ml dropping funnel, a gas inlet and a heating system. The reactor is cooled by means of an ice bath, and 37 ml of a 1.1M solution of butyllithium in hexane are then added dropwise while maintaining the temperature below 5° C. After stirring for 30 minutes at a temperature of 2° C., a solution of 2.28 g of 4-methyl-pent-3-enoic acid in 30 ml of anhydrous tetrahydrofuran is added. After stirring for 30 minutes, the reaction mixture is heated for 1 hour at 40° C.
After cooling to a temperature close to 20° C., air is introduced for 3 hours by means of a balloon, always with vigorous stirring. The reaction is followed by determination of the acids by proton nuclear magnetic resonance at 360 MHz.
After the reaction has ended, two 250 ml portion of water are added.
The aqueous phase which has been separated off by decanting is concentrated and then acidified with concentrated hydrochloric acid and finally extracted with ether.
The other phases, after drying and concentrating, give an oil which slowly crystallizes on cooling.
The crude product obtained contains 90% of 2-hydroxy-4-methyl-pent-3-enoic acid and 10% of 4-hydroxy-4-methyl-pent-3-enoic acid.
The 2-hydroxy-4-methyl-pent-3-enoic acid is separated off by filtration over fritted glass.
The 2-hydroxy-4-methyl-pent-3-enoic acid has the following physico-chemical characteristics:
melting point: 95°-98° C.
elemental analysis: C% calculated: 55.37 found: 54.76 H% calculated: 7.75 found: 7.28
infrared spectrum (KBr pellet), characteristic bands at: 3400 cm -1 (alcoholic OH), 3100-2300 cm -1 (acidic OH), 2980 cm -1 (CH 3 ), 1705 cm -1 (C═O, acid) and 1070 cm -1 (C--O, alcohol)
proton nuclear magnetic resonance spectrum (360 MHz, CDCl 3 , chemical shifts in ppm relative to hexamethyldisilane taken as reference): 5.13 (d, lH,═CH-); 4.85 (d, lH,═CH--CH(OH)-); 1.72 (2s, 6H, 2×CH 3 )
mass spectrum (m/e): M + =130.
The conversion rate of the 4-methyl-pent-3-enoic acid is 58%.
EXAMPLE 3 Preparation of 2-hydroxy-4-methyl-pent-3-enoic acid
The procedure of Example 2 is followed, but by sweeping the surface with air.
The conversion rate of 4-methyl-pent-3-enoic acid is 100%.
2-Hydroxy-4-methyl-pent-3-enoic acid is isolated in a yield of 87%.
4-Hydroxy-4-methyl-pent-3-enoic acid is obtained in a yield of 5%.
EXAMPLE 4 - Preparation of prenal from the α-hydroxy-acid
0.143 g of 2-hydroxy-4-methyl-pent-3-enoic acid, 5 ml of an aqueous solution containing 90% of acetic acid and 0.54 g of lead tetraacetate are introduced into a 50 ml flask fitted with a magnetic stirrer. The mixture is stirred for 1 hour at 25° C. 5 ml of 0.35M sulphuric acid are added, and the precipitated lead sulphate is separated off by filtration. The prenal is quantitatively precipitated in the filtrate in the form of the 2,4-dinitro-phenylhydrazone.
The yield is 70.3%.
EXAMPLE 5 Preparation of prenal from the α-hydroxy-acid
0.143 g of 2-hydroxy-4-methyl-pent-3-enoic acid, 5 ml of 1,2-dichlorobenzene and, in small portions, 0.54 g of lead tetraacetate are introduced into a 50 ml flask fitted with a magnetic stirrer. The mixture is stirred for 1 hour at 25° C. After decanting, analysis of the reaction mixture by gas chromatography shows that the conversion rate of the 2-hydroxy-4-methyl-pent-3-enoic acid is 100% and that the yield of prenal is 86%.
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The present invention relates to novel α-hydroxyacids of the general formula (I), to the process of preparing them and to the use thereof as intermediates allowing access to homologous lower aldehydes (such as prenal or citral) by oxidative decarboxylation. ##STR1##
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a pulse-width modulated (PWM) rectifier for converting a three-phase alternating current into a direct current by using a semiconductor device whose switching operation is controlled by a PWM signal.
[0003] 2. Description of the Related Art
[0004] In a motor control apparatus that drives a machine tool, industrial machine, robot, or the like, a converter (rectifier) is used to convert commercial power into DC power then supplies the DC power to an inverter that drives the motor.
[0005] In recent years, rectifiers using pulse-width modulation (PWM) are being widely used because of the need to reduce power supply harmonics and reactive power. In a PWM rectifier, switching losses occur because high-speed switching is performed using a semiconductor device. Accordingly, this type of rectifier has the problem that, compared with conventional rectifiers based on diodes, losses in the power converter increase and the size of the converter thus increases.
[0006] To solve this problem, the prior art has employed a method that reduces the PWM frequency in regions where the amplitude of the current is large. This method is effective in reducing losses in the power converter and suppressing the increase in the converter size.
[0007] However, the prior art method has had the disadvantage that the response of the control system degrades because the feedback sampling period becomes longer as the PWM frequency decreases.
[0008] JP9-252581A discloses a method in which the carrier frequency of the rectifier (PWM converter) is varied. Further, JP2004-48885A and JP63-290170A each disclose a power converter that produces power from DC voltage by pulse modulation and supplies the power to a load, such as an electric motor, with provisions made to switch the modulation scheme between a three-phase modulation scheme and a two-phase modulation scheme (more properly, a modified two-phase modulation scheme: Refer to “PWM Power Conversion System” by Katsunori Taniguchi, Kyoritsu Publishing Co., Ltd, PP. 96-98). JP2008-259343A discloses a converter-inverter constructed by connecting an inverter to a converter, with provisions made to employ the modified two-phase modulation scheme as the PWM modulation scheme for either the converter or the inverter.
SUMMARY OF THE INVENTION
[0009] An object of the invention is to provide a PWM rectifier wherein switching losses in a semiconductor device are reduced without degrading the response of a control system.
[0010] According to the present invention, there is provided a pulse-width modulated (PWM) rectifier for converting a three-phase alternating current into direct current by using a semiconductor device which is controlled by a PWM signal, comprising: a control unit which generates the PWM signal in accordance with a three-phase modulation scheme in which a first PWM voltage command synchronized to the three-phase alternating current is created based on a difference between an output voltage of the PWM rectifier and a target value thereof and in which the PWM signal is generated by comparing the first PWM voltage command with a PWM carrier having a constant amplitude and constant frequency, or a modified two-phase modulation scheme in which the PWM signal is generated by comparing with the PWM carrier a second PWM voltage command created by saturating one phase selected from among three phases constituting the first PWM voltage command in the three-phase modulation scheme to a maximum or minimum value of the PWM and by applying an increase or decrease, required to achieve the saturation, to the other two phases; a detecting unit which detects at least one parameter selected from among an input current, output current, input power, and output power of the PWM rectifier and a temperature of the semiconductor device; and a modulation scheme switching unit which compares a detection value from the detecting unit with a predetermined threshold value and, if the detection value is larger than the threshold value, switches the modulation scheme used in the control unit from a three-phase modulation scheme to a modified two-phase modulation scheme.
[0011] In regions where current is relatively weak, the three-phase modulation scheme is employed in order to minimize current ripple, while in regions where the amplitude of the current is strong and heating (due to switching losses) becomes a problem, the modulation scheme is switched to the modified two-phase modulation scheme, thereby reducing the number of switching operations to two thirds for the same PWM frequency, and the switching losses thus decrease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram showing the configuration of a PWM rectifier according to one embodiment of the present invention;
[0013] FIG. 2 is a waveform diagram explaining how a PWM signal is generated by comparing a PWM voltage command with a PWM carrier;
[0014] FIG. 3 is a waveform diagram explaining modulation percentage and overmodulation;
[0015] FIG. 4 is a waveform diagram explaining one example of a modified two-phase modulation scheme;
[0016] FIG. 5 is a flowchart illustrating a modulation scheme setting procedure;
[0017] FIG. 6 is a graph showing the relationship between the modulation percentage and the harmonic current rms value in the three-phase modulation scheme and the modified two-phase modulation scheme for comparison;
[0018] FIG. 7 is a waveform diagram explaining a second example of the modified two-phase modulation scheme;
[0019] FIG. 8 is a waveform diagram explaining a third example of the modified two-phase modulation scheme; and
[0020] FIG. 9 is a waveform diagram explaining a fourth example of the modified two-phase modulation scheme.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] FIG. 1 is a block diagram showing the configuration of a PWM rectifier according to one embodiment of the present invention.
[0022] In the PWM rectifier, a main circuit section 10 includes transistors 12 to 17 , diodes 18 to 23 , and a smoothing capacitor 24 connected as shown. The input side of the main circuit section 10 is connected to a three-phase power supply 30 via an AC reactor 26 and a current transformer 28 , and the output side is connected to a load 32 such as a PWM inverter.
[0023] An adder 36 outputs a difference (voltage difference) representing the deviation of the output voltage of the PWM rectifier, i.e., the voltage across the smoothing capacitor 24 , from a voltage command. A voltage control unit 34 takes as inputs the voltage difference supplied from the adder 36 and the voltage from the three-phase power supply 30 , and outputs a current command which is a signal synchronized to the three-phase power supply and having an amplitude proportional to the voltage difference. An adder 38 outputs a difference (current difference) representing the deviation of the current detected at the current transformer 28 from the current command.
[0024] When the modulation scheme selected by a modulation scheme setting unit 42 is a three-phase modulation scheme, a current control unit 40 takes the current difference itself as a PWM voltage command, compares it with a PWM carrier having a constant amplitude and constant frequency, and outputs the result of the comparison as a PWM signal for controlling the transistors 12 to 17 . On the other hand, when the modulation scheme selected by the modulation scheme setting unit 42 is a modified two-phase modulation scheme, the PWM voltage command generated in accordance with the modified two-phase modulation scheme as will be described later is compared with the PWM carrier, and the result of the comparison is output as the PWM signal.
[0025] Referring to FIG. 2 , a description will be given of how the PWM signal is generated by comparing the PWM voltage command with the PWM carrier. In FIG. 2 , PWM voltage commands for R phase, S phase, and T phase in the three-phase modulation scheme are indicated by solid lines, and the PWM carrier to be compared with them is indicated by a dashed line. The PWM voltage command for each phase is compared with the triangular-wave PWM carrier, and if the PWM voltage command is larger, the upper transistor 12 , 14 , or 16 in FIG. 1 is turned on and the lower transistor 13 , 15 , or 17 is turned off; on the other hand, if the PWM voltage command is smaller, the lower transistor 13 , 15 , or 17 is turned on and the upper transistor 12 , 14 , or 16 is turned off. As the value of the PWM voltage command for each phase varies, the ON period of each transistor connected to that phase varies; that is, as the value of the PWM voltage approaches the maximum value of the PWM carrier, the ON period of the upper transistor connected to that phase increases, and as it approaches the minimum value, the ON period of the lower transistor connected to that phase increases.
[0026] In PWM modulation, the modulation percentage (PWM modulation percentage) is defined by the following equation.
[0000] PWM modulation percentage (%)=(Amplitude of PWM voltage command)/(Amplitude of PWM carrier)×100 (1)
[0027] In PWM overmodulation regions where the PWM modulation percentage exceeds 100%, as shown in FIG. 3 , the number of switching operations decreases because the switching stops in the section where the PWM voltage command is larger than the maximum value of the PWM carrier as well as in the section where the PWM voltage command is smaller than the minimum value of the PWM carrier. In the example of FIG. 3 , for R phase, for example, the PWM voltage command exceeds the maximum value in the section where the phase is 60° to 120°, and becomes smaller than the minimum value in the section where the phase is 240° to 300°, and the switching stops in these sections.
[0028] Next, the modified two-phase modulation scheme will be described. In the modified two-phase modulation scheme, the PWM voltage command for one of the three phases in the three-phase modulation is saturated to the maximum or minimum value of the PWM carrier, and the resulting increase or decrease is equally applied to the other two phases to create the respective PWM voltage commands. In the example shown in FIG. 4 , in the section where the phase is 0° to 60°, the PWM voltage command for S phase in part (b) of the figure is saturated to the minimum value of the PWM carrier and, in the section where the phase is 60° to 120°, the PWM voltage command for R phase in part (a) is saturated to the maximum value of the PWM carrier. Since, in any section, one of the three phases is saturated to the maximum or minimum value of the PWM carrier, and the switching stops, the number of switching operations of the transistors 12 to 17 decreases to two thirds of that in the three-phase modulation scheme, and the switching losses thus decrease.
[0029] FIG. 5 shows one example of a modulation scheme setting procedure in the modulation scheme setting unit 42 ( FIG. 1 ). In the initial state, the three-phase modulation scheme which reduces current ripple is selected as the modulation scheme. In the modulation scheme setting procedure, first the modulation percentage defined by equation (1) is checked whether it exceeds 100% or not, i.e., whether it is in the PWM overmodulation state or not (step 1000 ); if it is in the PWM overmodulation state, the modulation scheme is set to the usual three-phase modulation scheme (step 1002 ).
[0030] If it is not in the PWM overmodulation state, then the condition based on which to effect switchover to the modified two-phase modulation scheme is acquired (step 1004 ), and the acquired switchover condition is compared with a switchover level (step 1006 ). If the acquired switchover condition equals or exceeds the switchover level, the modulation scheme is set to the modified two-phase modulation scheme (step 1008 ). Next, the switchover condition is compared with (switchover level—hysteresis) (step 1010 ); if the former is equal to or less than the latter, the modulation scheme is set to the three-phase modulation scheme. That is, hysteresis is provided in the switchover decision step performed using the switchover condition.
[0031] The switchover condition is preferably the amplitude of the input current acquired by the current transformer in FIG. 1 . If the amplitude of the input current is stronger than the amplitude switchover level, switching is made to the modified two-phase modulation scheme, but if it is not stronger than (switchover level—hysteresis), switching is made to the three-phase modulation scheme. Alternatively, the switchover condition may be selected from among the amplitude of the input current, the temperature acquired from a temperature sensor (not shown) provided near the transistors 12 to 17 , the output current acquired from a current sensor not shown, the input power, and the output power, or a combination of some of these switchover conditions may be used. When making a switchover decision using a combination of a plurality of decision conditions, it is preferable to make provisions so that if any one of the decision conditions exceeds its corresponding decision level, switching is made to the modified two-phase modulation scheme, and if none of the decision conditions exceed their corresponding (switchover level—hysteresis) values, switching is made to the three-phase modulation scheme.
[0032] In the above example, the usual three-phase modulation scheme is employed in regions where the current amplitude is weak; however, a scheme that superimposes on the voltage command a compensation signal having a frequency three times that of the voltage command, i.e., a scheme generally known as the third harmonic injection scheme, may be employed.
[0033] FIG. 6 shows a relationship, derived through simulation, between the modulation percentage and the harmonic current rms value in the three-phase modulation scheme and the modified two-phase modulation scheme for comparison. Since the number of switching operations in the modified two-phase modulation scheme decreases to two thirds of that in the three-phase modulation scheme, the number of switching operations in the modified two-phase modulation scheme for a PWM frequency of 6 kHz is equivalent to that in the three-phase modulation scheme for a PWM frequency of 4 kHz. However, as shown in FIG. 6 , in the PWM overmodulation region where the modulation percentage exceeds 100%, the characteristic degrades in the modified two-phase modulation scheme compared with the three-phase modulation scheme. It will, however, be noted that in the PWM overmodulation region, the number of switching operations decreases even in the three-phase modulation scheme, as earlier described with reference to FIG. 3 .
[0034] It is therefore desirable to maintain the three-phase modulation scheme in the PWM overmodulation region even if the switchover condition exceeds the switchover level, as described with reference to FIG. 5 .
[0035] FIGS. 7 to 9 show other examples of the modified two-phase modulation scheme. In the example shown in FIG. 7 , of the PWM voltage commands for R phase, S phase, and T phase, the strongest voltage command is saturated to the level equivalent to the maximum value of the PWM carrier, and the resulting increase is applied to the other two phases. In the example shown in FIG. 8 , of the PWM voltage commands for R phase, S phase, and T phase, the weakest voltage command is saturated to the level equivalent to the minimum value of the PWM carrier, and the resulting decrease is applied to the other two phases. In the example shown in FIG. 9 , the process of saturating the strongest voltage command to the level equivalent to the maximum value of the PWM carrier, as shown in FIG. 7 , and the process of saturating the weakest voltage command to the level equivalent to the minimum value of the PWM carrier, as shown in FIG. 8 , are repeated alternately. While FIG. 9 shows that the repetition period is set twice the period of the carrier and the two are synchronized to each other, the repetition period need not be set twice or an integral multiple of the period of the carrier or it is not necessary that they synchronized to each other.
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Disclosed is a PWM rectifier in which switching losses in a semiconductor device are reduced without degrading the response of a control system. In a PWM overmodulation region, the modulation scheme is set to a three-phase modulation scheme. In other regions, a switchover condition such as the amplitude of an input current is acquired and compared with a switchover level. If the switchover condition equals or exceeds the switchover level, the modulation scheme is switched over to a modified two-phase modulation scheme which reduces the number of switching operations to two thirds for the same PWM frequency.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in International Patent Application No. PCT/DK2010/000047 filed on Apr. 16, 2010 and Danish Patent Application No. PA 2009 00508 filed Apr. 17, 2009.
FIELD OF THE INVENTION
[0002] The invention relates to a sensor having a filter arrangement, downstream of which there is arranged a detector arrangement, and an evaluating device which is connected to the detector arrangement, the filter arrangement has at least a first filter, the suspect filter, which is configured as a band pass filter allowing the passage of a first predetermined band, the suspect band, at least one second filter, the reference filter(s), which is configured as band pass filters allowing the passage of a second predetermined band(s), the reference band(s), and where the detector arrangement has at least one detector associated with the at least one of the filters. The sensor uses the band pass filters to measure the temperature of an emitting source. The sensor with advantage could be utilized within the IR band, and could advantageously be used to detect CO 2 .
BACKGROUND OF THE INVENTION
[0003] Such a sensor, which is configured as a gas sensor, is known, for example, from U.S. Pat. No. 5,081,998 A. An IR radiation source is provided therein, which acts upon a total of four detectors by way of a filter arrangement. The filter arrangement has two filters having different pass characteristics. A first filter has a pass band for IR radiation that is absorbed by CO 2 . That filter is therefore also referred to as a “CO 2 filter”. The detectors arranged downstream are designated CO 2 detectors. The other filter has a pass band different therefrom which serves for determining a reference quantity. The detectors arranged downstream of that reference filter are referred to as reference detectors. Between the IR source and the two filters there is arranged a third filter which is referred to as a natural density filter and overlaps half of the first filter and half of the second filter. Accordingly, one of the two CO 2 detectors and one of the reference detectors receives only IR radiation that has passed both through the natural density filter and through either the CO 2 filter or the reference filter. In the evaluating device, the difference of the output signals of the two CO 2 detectors and the difference of the two reference detectors is formed. The two differences are then divided by one another. Such a CO 2 sensor is required, for example, for determining CO 2 in a patient's breath so as to be better able to monitor the patient during anaesthesia.
[0004] A disadvantage of such sensors is that they have a relatively high power requirement, and another disadvantage is the number of detectors required. The arrangement known from U.S. Pat. No. 5,081,998 A requires a source of radiation which, in any case for prolonged use, makes it unsuitable for battery-operated use. Furthermore, such an IR source generally requires a certain heating-up period, so that without a degree of prior preparation it is not always possible to carry out measurements when desired.
[0005] The problem underlying the invention is to simplify the use of an IR sensor, which is introduced in the sensor described in US 2008/0283753, wherein the pass band of a first filter is arranged within the pass band of a second filter and the evaluating device forms the difference of the signals of the detectors and normalizes it to the signal of a detector.
[0006] That configuration makes it possible to evaluate substantially more IR radiation. The IR radiation is therefore not divided into two separate ranges, with each detector detecting only one range. Instead, one detector detects IR radiation having a pre-set spectral range, which also includes, for example, the absorption spectrum of the gas being determined, here CO 2 . The other detector detects an IR spectrum from a sub-range thereof, which does not include the absorption spectrum of the gas being determined. The sensitivity of the sensor is thus considerably increased, that is to say only relatively low demands are made for the supply of IR radiation to the sensor. Because the difference between the output signals of the detectors is formed, an interfering signal, for example background noise or the like, is eliminated. The normalisation of the difference to the output signal of a detector enables fluctuations in the intensity of the IR radiation to be compensated. It is also possible to use more than two sensors with a correspondingly greater number of filters, the individual pass ranges then overlapping accordingly. With such a sensor it is also possible to obtain other information, for example relating to temperature, to movement in the room, to the number of persons in the room, etc. Because it is possible to detect substantially more radiation, the power consumption can be reduced, so that the necessary power can also be supplied by a battery. That in turn gives greater freedom in terms of local mounting and use. The sensor can transmit its signals wirelessly.
[0007] The pass band of the first filter is preferably larger than the pass band of the second filter. Accordingly, the first filter, in addition to including the spectral range allowed to pass by the second filter, also includes the spectral range in which IR radiation is absorbed.
[0008] The two filters preferably have a common cut-off wavelength. That simplifies evaluation. The difference between the output signals of the detectors can then readily be formed without additional calculation steps being necessary. The cut-off wavelengths are the wavelengths that define, that is to say limit, the pass bands. They are referred to as “lower wavelength” and “upper wavelength”.
[0009] It is how ever a known situation, that the amount as well as the spectral distribution of radiation of a emitter has a dependence of the temperature of the emitter. This is given by the well known Planck's distribution of radiation. Given a temperature of the emitter, a Planck curve then gives the dependence of the radiation to the wavelength, where the Planck curves has a maximum radiation at some wavelength, the maximum radiation value as well as the wavelength of the maximum radiation being temperature dependend.
[0010] Using a natural source in sensor systems such like the one described in for example US 2008/0283753, would make the pass bands of the filters change in energy (or in other words, the radiation intensity density) over the band of wavelengths. The temperature of such a natural source is usually not known, and even less controllable.
[0011] This construction is able to compensate for changes in the intensity of radiation of the light source, however, is not robust to for example temperature changes of the light source.
[0012] It is the object of the present invention to introduce methods to solve these problems of the present sensors, and a sensor utilizing the solutions, by introducing a way of estimating the temperature of the source.
SUMMARY OF THE INVENTION
[0013] It is therefore one object of the present invention to introduce a method to at least estimate the temperature of the emitter source, and to use this to correct or adjust the measurements of the sensor.
[0014] The present invention solves these problems by introducing that the suspect filter and the reference filter(s) has different cut-off wavelengths. The “lower wavelength” is the lowest wavelength from
[0015] which the filters allow passage of radiation, and the “upper wavelength” is the highest wavelength higher that the lower wavelength, from which the filters shuts off passage of radiation.
[0016] The ranges of allowed wavelengths of the suspect filter(s) are in the following being referred to as the “suspect band(s)”, and the allowed wavelengths of the reference filter(s) are in the following being referred to as the “reference band(s)”.
[0017] As written, the suspect lower wavelength in the present invention is different to the reference lower length(s), and the suspect upper wavelength is different to the reference upper wavelength(s). This has the advantage that changes, such like the spectral distribution of the intensity of the incoming radiation, for example caused by temperature fluctuations of the source, can be compensated by distributing the reference band(s) above and below the suspect band. In one preferred embodiment of the present invention, this distribution is so that by a change in temperature, the increase in radiation intensity (or intensity density or energy) over the reference band roughly equals the increase in radiation intensity (or intensity density or energy) over the suspect band.
[0018] In one alternative or additional embodiment, the mean value, or average, of the radiation intensity density (or energy) over the suspect band roughly equals the mean value, or average, of the radiation intensity density (or energy) over each of the reference bands.
[0019] In one alternative or additional embodiment, the radiation intensity density (or energy) over the suspect band roughly equals the mean value, or average, of the radiation intensity density (or energy) over the whole of the combined reference bands. (the ‘reference filter system band’ is the combined reference bands of all the reference filters).
[0020] In another alternative or additional embodiment, the radiation intensity density (or energy) over the suspect band roughly equals the mean value, or average, of the radiation intensity density (or energy) of one of or each of the reference bands.
[0021] In yet another alternative or additional embodiment, the radiation intensity density (or energy) roughly is the same for each of the reference bands.
[0022] Measuring the average radiation at two relatively narrow bands of wavelengths would make it possible by Planck's law to make an estimation of the temperature of the emitter. This is or example done by indentifying the correct Planck curve so to speak, and thereby calculating the temperature.
[0023] This is the main idea of this present invention, where either the suspect and reference filter(s) in cooperation or reference filters alone, may form such bands for temperature estimation. The temperature measurements can be used to compensate the temperature dependency in gas measurements and thereby gain more accuracy in measuring the gas concentration.
[0024] The filters of the present invention may be formed by filter elements in series, or by one single filter element operating both as suspect filter and reference filter(s). When two or more filters are arranged as filter elements in series, they are arranged one after the other in the radiation direction, that is to say between the radiation source(s) and the detectors.
[0025] The sensor with advantage may operate within any radiation wavelength, and the source may be any radiation source.
[0026] The example in the following describes a sensor for determining the CO 2 content in an environment where a IR source would be preferred as light source, however, any other substances than CO 2 would also apply to the present invention, just as any other light source than within the IR band would apply.
[0027] In a further embodiment of the present invention, at least one reference filter (to be called the first reference filter) has a reference band, called the first reference band, with a wider span of wavelengths than the suspect band, where the first reference lower wavelength of this first reference filter is at a lower wavelength than the suspect lower wavelength, and the first reference upper wavelength of this first reference filter has a higher wavelength than the suspect upper wavelength. In this manner, the suspect band overlaps the first reference band.
[0028] In this embodiment, the centre wavelength of the first reference band (the first centre reference wavelength) and the centre wavelength of the suspect band may be the same, or may be different.
[0029] For a change in temperature, the relative change in intensity in the suspect and reference band must be equal in order for the temperature dependency to cancel out.
[0030] When using radiation sources, actively powered or natural the relative change in intensity depends unlinearly on the wavelengths spanned by the bands. Therefore the unmatching centre wavelength can be introduced to improve stability to temperature drift.
[0031] In this example, the reference filter(s) advantageously has a pass band that is from 0.2 to 1 μm greater than the pass band of the suspect filter. It is desirable for the suspect filter to cover basically only a relatively narrow wavelength range or spectral range of the radiation spectrum, for example the range in which IR radiation is absorbed by CO 2 . The range indicated is sufficient for this. The risk that absorption by other gases will have an adverse effect on the measurement result and falsify that result is kept small.
[0032] It is preferable here for the first reference filter to have a pass band in the range from 4 to 4.5 μm and the suspect filter to have a pass band in the range from 4.1 to 4.4 μm. In dependence upon the gases or other quantities being detected, those spectral ranges can of course also be shifted.
[0033] In another preferred embodiment of the present invention, the system comprises a first and a second reference filter with a first and second reference band respectively (together constituting the combined reference bands), where the first and second reference bands are non-overlapping, meaning they span no common wavelengths. This may be an advantage if there are other gasses etc. in the environment than the gas(ses) of interest, with absorption bands in the vicinity of the suspect band, that could influence the measurements, in that it is difficult to avoid overlapping a reference band with such ‘pollution’ bands. By ensuring that at most one references band is affected by such a ‘polluting’ absorption band, it will be known that at least the other is unaffected.
[0034] In one preferred version of this embodiment, at least one of the first or second reference bands overlaps the suspect band, meaning that the first reference upper wavelength is at a higher wavelength than the suspect lower wavelength, and/or the second reference lower wavelength is at a lower wavelength than the suspect upper wavelength, but at a higher than the first reference upper wavelength, thus leading to the first and second reference bands extending at each side of the suspect band, but without overlapping.
[0035] In another preferred version of this embodiment, the first reference upper wavelength is at a lower wavelength than the suspect lower wavelength, and the second reference lower wavelength is at a higher wavelength than the suspect upper wavelength, thus leading to the first and second reference bands extending at each side of the suspect band.
[0036] In an alternative embodiment, the first and second reference bands are overlapping having at least one common wavelength.
[0037] In an especially preferred configuration, the sensor uses the natural radiation, such as IR radiation, from the environment. There is therefore no need for a source of radiation that needs a separate power supply and accordingly has a certain power requirement. IR radiation is generally present everywhere, even when there is no incident sunlight. In principle every body emits a certain amount of thermal radiation. Because it is then possible to do without an IR radiation source, the “measurement range” is also broadened, that is to say it is possible to monitor relatively large areas of a room for the content of the gas in question. This facilitates the monitoring and establishment of a “personal room climate” or the indoor air quality. It is unnecessary first to conduct the air in the room to a sensor where it is passed between the source of IR radiation and the detectors with upstream filters. It is sufficient for the sensor to be arranged at a point in the room where it can, as it were, “survey” the volume of air to be monitored. In that case, the gas sensor can, as it were, detect the averaged gas concentration in a simple way. The sensor therefore determines an average value, which, particularly for the personal room climate, constitutes a substantially better measurement result. Of course, it is also possible to use the sensor to improve the technology of sensors that operate with lamps or other means of lighting. When natural or ambient IR radiation is used, the energy of the light means can be reduced. That results in longer maintenance intervals and a longer service life.
[0038] The evaluating device preferably normalizes the difference to the signal of the first detector. In other words, for normalisation the signal containing for example the CO 2 content is used. That procedure results in a somewhat greater dynamic performance.
[0039] The ability for the sensor to react to changes in the temperature of the source is especially relevant for normalisation, since the normalization only works at a certain temperature, and the filter setup typically is made only for a certain temperature range. In order to cover a wider temperature range, a compensation routine is implemented by exactly deriving the temperature of the emitter. Furthermore the information derived can be used in a self-check algorithm when not using a natural light source, to estimate if the lifetime of the emitter, or light source, is exceeded or close to exceed.
[0040] The filters preferably contain CaF 2 , germanium or silicon. The filter and any other parts of the sensor device where it would make sense, preferably has an anti-reflective coating in order to improve transmission.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] The invention will be described herein below with reference to a preferred exemplary embodiment in conjunction with the drawings.
[0042] FIGS. 1 and 2 illustrates a bands on a Planck curve
[0043] FIG. 3 is a diagrammatic view for explaining the operating principle of the present invention;
[0044] FIG. 4A-E shows, in diagrammatic form, pass bands of two or three filters without any wavelength dependence of the radiation intensity shown.
[0045] FIG. 5 shows, in diagrammatic form, the amount of energy that can be detected by detectors;
[0046] FIG. 6A-D is a block circuit diagrams for explaining different embodiments of the structure of the sensor;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] FIG. 1 illustrates a general Planck curve having a maximum radiation at the wavelength λmax, and having a continuously decreasing radiation for increasing wavelengths above λmax, so using a band Δλ between two such wavelengths λ 1 and λ 2 . The radiation R 1 at the lower wavelength λ 1 being larger than the radiation R 2 at the upper wavelength λ 2 .
[0048] This would give problems when using such a band Δλ in a measurement, since a change of intensity in that band might either be due to a simple change in intensity of the incoming light, or due to a change of the temperature of the emitter.
[0049] FIG. 2 shows the same Planck curve, but where two bands Δλ 1 and Δλ 2 are seen. Knowing the average radiation in such two bands makes it possible by Planck's distribution of radiation to make an estimation of the temperature, by calculating the ratio of the signal of these two bands, assuming that there is no absorption taking place that affects the radiation intensity reaching the detector.
[0050] FIG. 3 shows a diagrammatic view of a gas sensor ( 1 ) for determining for example the CO 2 content (carbon dioxide content) in a measurement region ( 3 ), where the sensor ( 1 ) comprises a detection part ( 2 ). The measurement region may be, for example, a room or the portion of a room in which the personal room climate is to be regulated. A sun symbol ( 4 ) represents a radiation source, such as for example a natural IR source, passive sources, or any imaginable active source (sunlight, laser, light diodes, controlled hated sources etc.) The sun symbol ( 4 ) serves here merely for explanation purposes. The gas sensor ( 1 ) also operates in the absence of sunlight, because in principle virtually any body radiates heat and thus generates IR rays.
[0051] In the example, a large number of CO 2 molecules are present in the measurement region ( 2 ), the CO 2 molecules being represented herein by small circles. The gas molecules ( 4 ) absorb IR rays in a specific spectral range, as represented by arrows ( 5 ). The greater the concentration of CO 2 , the lower the energy in a specific spectral range that can be detected in the gas sensor ( 1 ).
[0052] FIG. 6A shows, in diagrammatic form, a block circuit diagram for explaining the structure simple detecting part ( 2 ) of a gas sensor ( 1 ). The detecting part ( 2 ) has a filter arrangement ( 6 ), a detector arrangement ( 7 ) and an evaluating device ( 8 ). Further details, such as the housing, fixing means or the like, are not shown herein.
[0053] The shown filter arrangement has a first reference filter ( 10 ) and a suspect filter ( 9 ), where the two filters ( 9 ) and ( 10 ) have different pass characteristics, where one embodiment is shown in FIG. 4A . The first reference filter ( 10 ) allows passing of wavelengths within the firsts reference band RB 1 , and the suspect filter ( 10 ) allows the passing of wavelengths within the suspect band SB. In the following figures the radiation dependence of wavelength is not seen.
[0054] The embodiment in FIG. 4B shows the first reference band RB 1 spanning wider than the suspect band SB, but where the suspect band SB overlaps the first reference band RB 1 in such a manner, that the first reference band RB 1 comprises the same wavelengths as the suspect band SB. The first reference lower wavelength RLW 1 therefore is at a lower wavelength than the suspect lower wavelength SLW, and the first reference upper wavelength RUW 1 has a higher wavelength than the suspect upper wavelength SUW. The first reference band RB 1 has a first centre wavelength RCW 1 , and the suspect band has a suspect centre wavelength SCW. The figure shows the two bands having a common centre wavelength RCW 1 and SCW.
[0055] FIG. 4B shows a related embodiment to that shown in FIG. 4A , only where they dissimilar centre wavelengths RCW and RCW 1 . For a change in temperature, the relative change in intensity in the suspect and reference band must be equal in order for the temperature dependency to cancel out. When using radiation sources, actively powered or natural the relative change in intensity depends unlinearly on the wavelengths spanned by the bands. Therefore the unmatching centre wavelength can be introduced to improve stability to temperature drift.
[0056] FIG. 4C shows another embodiment where a second reference filter ( 20 ) has been introduced into the system spanning over a second reference band RB 2 extending from a second reference lower wavelength RLW 2 to a second reference upper wavelength RUW 2 . The shown embodiment further has the suspect band SB only partly overlapping both the first and second reference bands RB 1 and RB 2 in such a manner, that the suspect lower wavelength SLW is between the first reference lower wavelength RLW 1 and the first reference upper wavelength RUW 1 . The suspect upper wavelength SUW is between the second reference lower wavelength RLW 2 and the second reference upper wavelength RUW 2 . The shown embodiment has the first reference upper wavelength RUW 1 being higher than the second reference lower wavelength RLW 2 , but in other embodiments the first and second reference bands RB 1 and RB 2 might not overlap, meaning that the first reference upper wavelength RUW 1 would be lower than the second reference lower wavelength RLW 2 .
[0057] FIG. 4D shows an alternative embodiment with two reference filters ( 10 ) and ( 20 ), where none of the reference bands RB 1 and RB 2 at least substantially overlaps the suspect band SB, at least, but extends at each side of it, here meaning, that the first reference upper wavelength RUW 1 is not higher than the suspect lower wavelength SLW, but could optionally be the same, and the second reference lower wavelength RLW 2 is not lower than the suspect upper wavelength SUW, but could optionally be the same. The figure shows the two reference bands RB 1 and RB 2 having substantially the same pass range of wavelengths, but as seen in FIG. 2E this may not be the case, the two reference bands RB 1 and RB 2 might have very different pass ranges of wavelengths.
[0058] The relative positions and sizes of the bands depends on a number of factors, such as the tolerances of the edges of the filters, the width of the suspect band pass, the distribution of the absorption lines of the suspect band, and of any other gasses that might cause cross sensitivities.
[0059] In the example of the sensor ( 1 ) operating as a CO 2 sensor, there is a spectral range λ (CO 2 ) in which IR radiation is absorbed by CO 2 . That spectral range is located at about from 4.2 to 4.3 μm. Accordingly, the suspect band SB could with advantage have a suspect lower wavelength SLW at about 4.0 μm and a suspect upper wavelength SUW at about 4.5 μm, or with an even more narrow range of the suspect band from 4.1 μm-4.4 μm, or any other band covering the spectral range of CO 2 The reference start and upper wavelengths then with advantage could extend about 0.5 μm above and below the suspect lower wavelength SLW and suspect upper wavelength SUW respectively.
[0060] FIG. 5 illustrates a first reference band RB 1 and the suspect band SB of the first embodiment of the invention as seen in FIG. 3 , where the suspect band has a unreduced energy indicated by reference letter A. That energy is reduced by an amount C which is absorbed by for example CO 2 . The two sections of the first reference band RB 1 extending at each side of the suspect band each has an energy indicated by reference letters B. That energy is virtually constant, because it is not affected by for example CO 2 .
[0061] The different energies are then detected by the detector arrangement ( 7 ). The detector arrangement ( 7 ) has a first detector ( 15 ) which detects the for example IR radiation which passes through the suspect filter ( 9 ), and a second detector ( 16 ) which detects the for example IR radiation which passes through the first reference filter ( 10 ). The two detectors ( 15 ), ( 16 ) can be in the form of thermoelectric elements which are also known as “thermopiles”. In dependence upon the for example IR radiation that occurs, each detector generates a voltage or a current, that is to say an electrical quantity, which is the greater the more IR radiation is incident. Accordingly, the first detector ( 15 ) generates a signal S 1 and the second detector ( 16 ) generates a signal S 2 .
[0062] A thermopile sensor is obtainable, for example, from PerkinElmer Optoelectronics GmbH, D-65199 Wiesbaden, Germany.
[0063] FIG. 6A shows one simple embodiment of a construction of a filter arrangement ( 6 ), where the suspect filter ( 9 ) comprises two filter elements ( 11 ) and ( 12 ), the first suspect filter element ( 11 ) defining the suspect upper wavelength SUW and having a lower wavelength lower than the suspect lower wavelength SLW. The second suspect filter element ( 12 ) defines the suspect lower wavelength SLW and has an upper wavelength substantially higher than the suspect upper wavelength SUW. In the same manner the first reference filter ( 10 ) comprises two filter elements ( 13 ) and ( 14 ) defining the first reference upper wavelength RUW 1 and the first reference lower wavelength RLW 1 respectively. Depending on the number of filters like ( 9 ) and ( 10 ) introduced into the system, any number of such constructions of filter elements ( 11 ), ( 12 ), ( 13 ) and ( 14 ) may be introduced into the filter arrangement ( 6 ). Some filter elements in this and any other embodiment may be common to two or more of the filters when the filters have the same end and/or lower wavelength, this being illustrated in FIG. 6B , where the two ‘upper’ filter elements ( 11 ) and ( 13 ) is one common filter element.
[0064] FIG. 6C shows a similar sensor having a extra reference filter, the second reference filter ( 20 ), and where each filter only has a single filter element ( 21 , 22 , 23 ) comprising the desired band pass characteristic both for the upper and lower wavelengths, the suspect filter ( 21 ) thus both defining both the suspect lower wavelength SLW and upper suspect wavelength SUW. The first reference filter ( 22 ) defining both the first reference upper and lower wavelengths RUW 1 and RLW 1 , and the second reference filter ( 23 ) defining both the second reference upper and lower wavelengths RUW 2 and RLW 2 . The two filter elopements ( 22 , 23 ) are in this illustrated embodiment connected to the same detector ( 16 ) though in reality what would be none, is to add their signals mathematically after they have been acquired by for example two separated Thermopiles.
[0065] FIG. 6D shows an embodiment related to that of FIG. 6C , only where a third detector ( 24 ) is connected to the second reference filter ( 20 ).
[0066] It shall be noted that any combination, permutation, number and positioning of filter elements ( 11 , 12 , 13 , 14 ) as for example disclosed in FIGS. 5A-D would apply to the present invention.
[0067] In general the sensor could also be used to measure more than one gas, then just including the needed number of sensors, detectors etc., as it will be known to a craftsman.
[0068] Because, in a thermopile sensor, usually a temperature measurement is carried out (because the output signal varies with temperature), measurement of the temperature around the sensor has already been incorporated. As it is conceivable that the radiation temperature of the room is also obtainable by means of the sensor, it is possible on the basis of those two measurements simultaneously to obtain directly an operating temperature which can then be used for controlling the room temperature or something quite different.
[0069] In connection with IR it is also conceivable that measurement of a movement in the room is directly possible with the sensor, which can then be used, for example, for controlling a ventilating system, which, for example, is activated only in the event of a movement indicating that there is someone in the room. On the basis of various movement measurements it is also conceivable that it would be possible to estimate the number of people in the room, such an estimate also being usable for control purposes, so that the room temperature or the ventilation is controlled/modified in dependence upon the number of people in the room.
[0070] The basic sensor of this invention such as the one seen in FIG. 6A operates by the two signals S 1 , S 2 being supplied to the evaluating device ( 8 ). Accordingly, this gives
[0000] S 1 =a ( I CO 2 n )
[0000] S 2 =a ( I refn )
[0071] where I CO 2 is the electrical quantity, for example the current or the voltage, containing the information relating to the IR absorption, while I ref is the reference quantity that is not affected by the IR absorption. When the difference between S 1 and S 2 is formed (the “effective reference” being the part of the reference band which does not include the suspect band), for which purpose a difference former ( 17 ) is shown diagrammatically, the following quantity is obtained:
[0000] S 1 −S 2 =a ( I CO 2 −I ref )
[0072] That difference S 1 −S 2 is normalized to the output signal S 1 of the first detector ( 15 ), so that a signal S 3 is obtained.
[0000]
S
3
=
S
1
effectiveReference
=
(
S
2
-
S
1
)
=
a
(
I
CO
2
)
a
(
I
Ref
)
[0073] The sensor of this invention may be used to measure any kinds of gases, such like for example nitrogen, nitric oxides, oxygen or CO, and is not even limited to measure gasses, but may also be used to measure the suspect in other forms like liquids and solids. When changing suspect from CO 2 , the pass bands would have to be shifted accordingly, for example the absorption band of H2O is around 2.7 μm
[0074] Knowing the temperature of the emitter, or light source, makes it possible to corrugate, or normalize, quantities like I ref and I n , and/or signals like S 1 and S 2 , so to speak removing the temperature, and/or by normalization removing the wavelength dependence of the bands like the suspect and reference bands.
[0075] The sensor of the present invention may further comprise any possible other optical components, for example a sapphire window, that acts as additional band pass filter, reflectors, a collecting device, being a device that gathers or focuses for example IR radiation, for example a collimator, positioned upstream of the sensor, etc.
[0076] It is also possible to use such a sensor directly for waste gas monitoring. For that purpose, it is installed in the chimney or exhaust. Particularly in the case of heating systems, combustion can then be controlled with the aid of the output signals of the sensor (or of a plurality of sensors).
[0077] This invention is not excluded to the above descriptions and drawings, any permutation of the above descriptions and drawings, including any number and permutations of filters such as suspect filters ( 9 ) and reference filters ( 10 , 20 ), filter elements ( 21 , 22 , 23 ), detectors ( 15 , 16 , 24 ) etc. would also apply to the present invention.
[0078] Further, this invention is not excluded to measuring gasses, the sensor may as well be implemented in measuring substances in general being a part of a media, where the media is not excluded to be a gas it self, but could for example be a liquid.
[0079] Although the invention above has been described in connection with preferred embodiments of the invention, it will be evident for a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims.
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The invention relates to a sensor having a filter arrangement, downstream of which there is arranged a detector arrangement, and an evaluating device which is connected to the detector arrangement, the filter arrangement has at least a first filter, the suspect filter, which is configured as a band pass filter allowing the passage of a first predetermined band, the suspect band, at least one second filter, the reference filter(s), which is configured as band pass filters allowing the passage of a second predetermined band(s), the reference band(s), and where the detector arrangement has at least one detector associated with the at least one of the filters. The sensor uses the band pass filters to measure the temperature of an emitting source. The sensor with advantage could be utilized within the IR band, and could advantageously be used to detect CO 2 .
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of application Ser. No. 09/514,269, which is a continuation of International Application PCT/DE98/01777, filed Jun. 29, 1998, which designated the United States, now abandoned.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention concerns a long-fiber foam composite and components fabricated therefrom.
[0004] According to the state of the art, fleeces, mats, and similar padding of fibers and other longitudinally oriented structures with a high degree of thinness are bound such that they are:
[0005] mechanically fastened, e.g. through needling, quilting, felting;
[0006] welded through thermobonding if a thermoplastic material is used partly or wholly for fibers and similar; and
[0007] attached through application of adhesives by dipping, spraying, lubrication, and the like.
[0008] Foam materials and foam composite materials are known in which fibers, fleeces, fabric, and similar structures are inserted as reinforcement and in which the foam exerts a cohesive effect. This type of padding is generally referred to as a “nonwoven”.
[0009] The above products and processes possess a number of limitations, they include:
[0010] the mechanical fastening methods lead unavoidably to a thickening of the padding, which is undesirable for the majority of areas of application, especially for insulating materials;
[0011] the thermal bonding with mono-component or bi-component fibers mostly requires, depending on the area of application, a polymer fraction of between 15% and 50%. Many proven products can be fabricated in this way. But every synthesis is associated with high energy consumption and therefore with high emissions. Furthermore, chemical or synthetic fibers have high costs. Dipping and spraying is predominantly carried out with elastomers, but also with duromers and to some extent with mineral binding agents. In combination with elastomers, for example, this process allows outstanding cushioning materials to be produced. But the consumption of binding agents is high and, therefore, so is the costs and the emissions.
[0012] As a non-woven padding material for automobile seats, upholstered furniture and similar, most natural fibers have the disadvantage that they are pressed together during use, i.e. “flattened”. The lack of restoring forces of most natural fibers results in that they then remain in the flattened state.
[0013] International Patent Application No. WO 93/07318 to Nieminen et al. discloses products and processes for producing paddings, or upholsterings for clothing, furniture, and beds. The starting material used by Nieminen et al. are as follows: non-fluid and non-adhesive pieces of foam varying in size from 2 to 20 mm and short thermoplastic binder fibers having a maximum size of 40 to 50 mm. The pieces of foam and binder fibers are mixed with one another to produce “wad mats”, also called “padding mats” or “upholstery mats”. They are then thermally bonded to one another. In Nieminen et al., the pieces of foam form a matrix (i.e., the foam forms the majority of the material used) and are the actual paddings or upholsterings. The pieces of foam are bound by the binder fibers to prevent escape or expulsion from the item of clothing, the furniture upholstery, or the mattress. The pieces of foam, which are foamed in advance and are non-fluid and non-adhesive, are composed of foam wastes of all types: i.e., by-products of foam processing. However, the foams could be produced from plastics, by adding blowing agents to these and foaming them and then permitting them to cure and only then breaking up the cured foam to give pieces: e.g. by shredding, chopping, tearing, or the like. The final products are “wad mats”. Wad mats are also known as padding mats or upholstery mats in which the pieces of foam are the actual padding or upholstering material, which is prevented from escaping by binder fibers. In Nieminen et al., the linkage to the binder fibers always takes place tangentially by thermal bonding because the foam bodies are non-fluid and therefore are forced to contact the binder fibers tangentially.
[0014] U.S. Pat. No. 5,646,077 to Matsunaga et al. discloses bonding fibers via thermal bonding of the novel fiber, which in turn holds the principal fibers together in a known manner by mechanical networking/felting. The binder fiber is a polyester copolymer that includes ε-caprolactone as polyester constituent and has a melting point of not less than 100° C. Matsunaga et al. does not teach or suggest a system for producing nonwovens with zones of different density.
[0015] U.S. Pat. No. 6,159,879, which has identical inventorship as the instant application, discloses a, “Building Material Made from Bast Fibers, Shives, and a Binder.” In this patent, a foam is only used as part of a matrix; see claim 6. The foam does not appear as small foam bodies that themselves do not form a matrix.
[0016] Likewise, U.S. Pat. No. 6,207,244, which has identical inventorship as the instant application, discloses a, “Structural Element and Process for Its Production.” This patent describes fibers that are embedded in a foam matrix; see claims 1 and 7. These matrices cannot be expanded by subsequent foaming. Accordingly, they also cannot be used in moldings that utilize the pressure created by the subsequent foaming.
SUMMARY OF THE INVENTION
[0017] It is accordingly an object of the invention to provide a long-fiber foam composite which overcomes the above-mentioned disadvantages of the prior art devices of this general type, in which long fibers are bound into a loose but dimensionally stable nonwoven with good resilience characteristics.
[0018] With the foregoing and other objects in view there is provided, in accordance with the invention, a long-fiber foam composite. The long-fiber foam composite includes small foam body particles. The small foam body particles are formed from droplets of a binding agent and a foaming agent that have been expanded by foaming. In addition, the long-fiber foam composite includes a fiber mixture of long fibers that are only partially connected to each other via the small foam body particles for forming a low density nonwoven. The small foam body particles are disposed in the low density nonwoven in an expanded form and/or a non-expanded form during a formation of the low density nonwoven. The small foam body particles that are applied in the non-expanded form (i.e. as droplets of binding agent) are expanded through a reaction with or an activation of the foaming agent of the binding agent disposed in the low density nonwoven.
[0019] In accordance with an added feature of the invention, the small foam body particles are nodally disposed in the low density nonwoven and inserted into the low density nonwoven in one of the expanded form and the non-expanded form during a formation of the low density padding. In the low density padding, foam-free zones, stretched across by the long fibers alone, are formed between the small foam body particles.
[0020] In accordance with an additional feature of the invention, the long fibers are selected from the group consisting of natural fibers, chemical fibers, synthetic fibers, and inorganic fibers. In addition, the long fibers are primary fibers, recycled fibers or mixtures of the primary fibers and the recycled fibers.
[0021] In accordance with another feature of the invention, an expansion of the small foam body particles proceeds freely without volume restriction so that it is possible to achieve a minimally possible density through complete expansion of the small foam body particles. The expansion can be carried out using a double-belt press, a mold, and a similar predetermined volume resulting in the low density nonwoven having a predetermined density.
[0022] In accordance with yet another added feature of the invention, the fiber mixture contains expanded polymer fibers that are fused together with one another at crossing points through thermobonding. In this case, the polymer fibers contain a foaming agent that is activatable through a reaction or through an input of energy during or after the formation of the low density nonwoven and that an expansion can thereby be effected.
[0023] In accordance with yet another additional feature of the invention, formed molded parts are made, using a mold, from the low density nonwoven through an input of one of energy and pressure to the mold. The formed molded parts may have zones compressed to different extents by the mold. A coating of an adhesive or a foam coating capable of adhering is applied to at least one side of the formed molded parts.
[0024] In accordance with a concomitant feature of the invention, a decorative surface coating material or a surface coating material having a technical function are glued on or foamed on the formed molded parts.
[0025] In accordance with a further object of the invention, the long fibers are natural fibers.
[0026] In accordance with a further object of the invention, the long fibers form a matrix. This contrasts the prior art where the small soft particles form a matrix.
[0027] In accordance with a further object of the invention, the small foam body particles are fluid and adhesive at room temperature initially when added to the long fibers. This allows the long fibers to be embedded in so as to cross and form nodes within the small foam particles.
[0028] In accordance with a further object of the invention, the small foam body particles have a diameter less than five millimeters (<5 mm), and preferable between one and two millimeters (1-2 mm), before being foamed. Ultimately, the small foam body particles have a diameter remaining less than 20 mm.
[0029] In accordance with a further object of the invention, the long fibers have a length from 30 mm to 150 mm, and preferably from 70 mm to 80 mm.
[0030] In accordance with a further object of the invention, an automobile door can be fashioned by including a long-fiber foam composite as described above.
[0031] In accordance with a further object of the invention, a method for manufacturing a long-fiber foam composite includes the following steps. The initial step is providing a fiber mixture of long fibers. The next step is connecting at least some of the long fibers with small foam body particles in an unexpanded state. The next step is expanding the small foam body particles with a binding agent having a foaming agent. The next step is embedding the long fibers nodally at crossing points of the long fibers during the expanding step to form a low-density nonwoven.
[0032] The term “node” (and nodally) refer to a fiber and a binding agent that surrounds the fiber. Nodes should not occur at crossing points of the fibers. If the nodes did occur at crossing points, shifting is impossible; therefore, no volume increase would occur when the binding agent is foamed.
[0033] In accordance with a further object of the invention, the method includes expanding the small foam body particles by reacting the small foam body particles with the foaming agent of the binding agent.
[0034] In accordance with a further object of the invention, the method includes expanding the small foam body particles by activating the foaming agent of the binding agent.
[0035] In accordance with a further object of the invention, the connecting step includes disposing nodally the small foam body particles in the unexpanded state on the long fibers.
[0036] In accordance with a further object of the invention, the method includes spacing the small foam body particles along the long fibers to create foam-free zones.
[0037] In accordance with a further object of the invention, the method includes free expanding the small foam body particles without volume restrictions.
[0038] In accordance with a further object of the invention, the method includes controlling a density of the low density nonwoven by controlling a volume of the low density nonwoven.
[0039] In accordance with a further object of the invention, the method includes molding the low density nonwoven to control the volume and the density.
[0040] In accordance with a further object of the invention, the method includes using a belt press to control the volume and the density.
[0041] In accordance with a further object of the invention, the method includes the steps of including polymer fibers in the fiber mixture; and thermobonding the polymer fibers at crossing points to fuse the polymer fibers.
[0042] In accordance with a further object of the invention, the method includes the step of including the foaming agent in the polymer fibers.
[0043] In accordance with a further object of the invention, the expanding step includes inputting energy to activate the foaming agent.
[0044] In accordance with a further object of the invention, the method includes enclosing the low density nonwoven in a mold; and heating the mold to activate the foaming agent.
[0045] In accordance with a further object of the invention, the method includes enclosing the low density nonwoven in a mold; and pressurizing the mold to activate the foaming agent.
[0046] In accordance with a further object of the invention, the method includes forming zones in the low density nonwoven by compressing parts of the mold to different extents.
[0047] In accordance with a further object of the invention, the method includes adding an adhesive to at least one side of the low-density nonwoven.
[0048] In accordance with a further object of the invention, the method includes attaching a decorative surface coating to the low density nonwoven with the adhesive.
[0049] In accordance with a further object of the invention, the method includes attaching a surface coating material having a technical function with the adhesive.
[0050] In accordance with a further object of the invention, the method includes the step of including a foam coating to at least one side of the low density nonwoven.
[0051] In accordance with a further object of the invention, the method includes attaching a decorative surface to the low density nonwoven with the foam coating.
[0052] In accordance with a further object of the invention, the method includes attaching a surface coating material having a technical function with the foam coating.
[0053] In accordance with a further object of the invention, the method includes selecting the long fibers from the group consisting of chemical fibers, synthetic fibers, and inorganic fibers.
[0054] In accordance with a further object of the invention, the method includes using natural fibers as the long fibers.
[0055] In accordance with a further object of the invention, the method includes selecting the long fibers from the group consisting of primary fibers, recycled fibers, and mixtures of the primary fibers and the recycled fibers.
[0056] In accordance with a further object of the invention, the method includes forming a matrix from said long fibers.
[0057] In accordance with a further object of the invention, the method includes adding the small foam body particles as a room-temperature fluid that is adhesive. Then, the long fibers are embedded within and crossed to form nodes within said small foam body particles.
[0058] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0059] Although the invention is illustrated and described herein as embodied in a long-fiber foam composite, an automobile door including the long-fiber foam composite, and a method for manufacturing the long-fiber foam composite, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0060] 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
[0061] [0061]FIG. 1 is a diagrammatic view of a foam body according to the prior art;
[0062] [0062]FIG. 2A is a diagrammatic view showing a nonwoven according to the invention with binder droplets introduced in unfoamed form between long fibers;
[0063] [0063]FIG. 2B is a diagrammatic view showing the nonwoven of FIG. 2A after foaming; and
[0064] [0064]FIG. 3 is a sectional view of an automobile door including a long-fiber foam composite according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0065] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a foam body according to the prior art; see especially Nieminen et al. WO 93/07318. The foam bodies 1 are cured and non-adhesive. The foam bodies are made from waste or from new foams made by shredding, breaking, and the like. The foam bodies compose the actual paddings or upholsterings. Accordingly, the foam bodies are the matrix. The binder fibers 2 are NUR polymer fibers or other fibers suitable in thermal bonding. The function of the binder fibers 2 is to bind the foam bodies together so that they do not escape, roll away, or form clumps. The foam bodies 1 and binder fibers 2 contact at fusion points 2 A. Because the foam bodies 1 are non-fluid, i.e. cured, they can enclose or flow around the binder fibers. Therefore, the binder fibers 2 and foam bodies 1 only touch tangentially; i.e. they binder fibers 2 do not penetrate the foam bodies 1 .
[0066] [0066]FIG. 2A shows a nonwoven according to the invention. The foamable binder droplets 2 can be in a previously foamed form when introduced between the long fibers 1 during formation of the nonwoven. This occurs when there is no desire to reduce the density below the level intrinsically brought about by the procedure for forming the nonwoven.
[0067] In contrast, if the density desired is lower than that possible via prior-art systems for forming a nonwoven, the binder droplets then have to be introduced in unfoamed form. Subsequent foaming then pushes the long fibers 1 apart. The long fibers 1 are then held internally (as opposed to tangentially) at coupling sites 3 by the droplets 2 , which then cure via drying or reaction. After curing, the fibers 1 are permanently fixed and the low density is set.
[0068] The long fibers 1 preferably have a length up to one-hundred-fifty millimeters (150 mm). The binder droplets 2 preferably include blowing agent, fluid, and as shown in FIG. 2A are yet to be foamed.
[0069] [0069]FIG. 2A shows that the fluid binder 2 wets the fibers 1 partially, i.e. only at some sites. FIG. 2A further shows that there is some enclosure of the long fibers by the binder droplets. This happens because the binder droplets 2 are fluid and the adhesive forces cause them to flow around and wet the surfaces of the long fibers. This phenomena increases as the size of the droplets increases and the viscosity decreases. The result is that, at the points of contact with the adhesive droplets 2 , the long fibers 1 do not remain on their surface but become integrated in them.
[0070] [0070]FIG. 2B shows the nonwoven from FIG. 2A after foaming to about twice its original height; note FIGS. 1, 2A, and 2 B are roughly all drawn to scale with each other. The reference numbers are the same as in FIG. 2A: long fibers 1 , binder droplets 2 , and coupling site 3 . The result according to the invention is a density is a density so low that it could not be achieved by the prior art.
[0071] According to the invention, the foaming may be free: i.e. without limitation of volume by a twin-belt press, mold, or the like. The result is a nonwoven with an extremely low density.
[0072] The density primarily depends on the amount of blowing agent introduced into the binder. In addition, the foaming may be limited in volume terms. For example, the volume can be limited by the production method to define densities and molding with zone-by-zone differences; e.g. for car doors.
[0073] In addition, when thermosets are used or used concomitantly, the molding produced by expansion pressure in the hot mold can be fixed directly then, in the mold.
[0074] The stresses resulting as a consequence of the foaming process do produce some degree of reorientation and stretching of the long fibers 1 . As a result, the long fibers 1 may be drawn into the foam droplets 2 . This can increase the strength of the bond at the coupling sites 3 .
[0075] In other words, the nonwoven is a mixture of long fibers 1 that are only partially bound together through small foam bodies 2 (i.e. binder droplets) formed as nodal points to produce a nonwoven of low density. When forming the nonwoven it is possible to insert the small foam bodies 2 formed as nodal points into the nonwoven in an expanded or non-expanded state. Whereby the small foam bodies 2 inserted in the non-expanded state can be expanded through reaction or through activation of a foaming agent previously inserted in a binding agent that expands when activated. In such an embodiment of the invention, foam-free zones stretched across by the long fibers 1 alone are formed between the small foam bodies 2 . As the long fibers 1 , it is possible to use natural fibers 2 , chemical fibers 2 , synthetic fibers 2 , or inorganic fibers 2 , both as primary fibers and also as recycled fibers or mixtures thereof.
[0076] There are many advantages of the solution according to the invention, they include loose fiber bundles (i.e. nonwovens), especially natural fiber bundles, which according to the state of the art are of only limited suitability as upholstery because of their lack of resilience, acquire good resilience through the use of elastomers or thermo-elastic materials for the formation of the small foam bodies 2 and thus become a high-quality upholstering material. In contrast to elastomer fiber bundles according to the state of the art, in which the fibers 1 are coated as far as possible with non-expanded elastomers, the only partial use of the elastomer results in considerable economies in consumption. The foaming makes the consumption even more economical. At the same time, the foaming also leads to improved upholstery characteristics and better dimensional stability and resilience after subjection to loading. The fiber structure can also be formed more loosely, whereby savings are made in the quantity of the fibers 1 used. It can be expected that it will be possible to build up a greater market for natural fibers through the solution according to the invention.
[0077] For purposes of heat insulation, the solution according to the invention enables the main existing problem of using natural fibers to be solved. It is considered a serious deficit that insulating fleeces made from the fibers 1 of flax, hemp, sheep wool, etc. settle with time through lack of intrinsic stiffness. Over the years, this leads to loss of a considerable part of the insulating effect.
[0078] By using the small foam bodies 2 according to the invention, the natural fibers 1 —and also other fibers 1 —can be bound to one another in a punctiform way with a minimized outlay on the binding agent through foaming. Above all, however, the small foam bodies 2 support the fibers 1 from within and ensure that they cannot collapse together over time.
[0079] Furthermore, if the expandable materials (i.e. the small foam bodies 2 ) are not expanded until after insertion between the fibers 1 , they drive the fibers 1 apart and effect a reduction in the density of the nonwoven, which would have been impossible to achieve without the process according to the invention. Since, as is known, the lower the density of an insulating material, the better it insulates, the process according to the invention not only provides the strived-for dimensional stability but also leads to an increase in the insulating performance beyond the natural extent.
[0080] It is known that the insulation effect derives not from the fibers 1 but from the air encapsulated in and between them. The lower the density of the fiber bundle or nonwoven, the easier it is for the air to move and thereby to reduce the insulating effect. This can be countered by protecting the insulating material from air movements from outside through lining with papers, film or other wind-proof materials, which is not shown. When forming the fleeces or other kinds of mats, such windbreaks can be attached directly to the insulating material in that the shaping process acts upon them. The bond between the fibers 1 and the windbreak can be produced, among other possibilities, through the small foam bodies 2 still being adhesive during the production process, or also through spraying on an adhesive. Windbreaks or layers intended to prevent convection within the fibers 1 can be attached on one side or both sides in the process according to the invention. Thin layers of foam or fine fleeces can also be considered as the windbreaks to be attached on one or both sides. The windbreaks can be formed as a decorative surface and/or may be formed as a surface having a technical function.
[0081] As a result of the invention, it is possible, at minimum cost, to achieve dimensional stability for light fleeces and to increase the restoring forces. The long fibers 1 glued in by a nodal configuration of the small foam bodies 2 ensure that the foam body 2 is under lateral tension and therefore that the undesirable lateral displacement and see-sawing movements typical for foam padding do not occur. The fact that only a part of the total volume is consumed by the foam 2 and the remaining part, although partially glued, is consumed by the open fibers 1 leads to especially good air permeability—a particular advantage for upholstery.
[0082] Suitable for the fabrication of the above foam composite are polymers, elastomers and also duromers in the state of the precondensate or pre-adduct. The insertion in an already expanded state should preferably be used if the intention is to form a bond to the fleece or other kind of padding without any additional reduction of the density of the padding.
[0083] The insertion of reactive expandable systems or subsequently expandable systems, e.g. through the subsequent input of energy, should preferably be used if it is intended that the expansion take place freely and it is also intended through the increase in the foam 2 to reduce the density of the fleece or other kind of nonwoven to a greater extent than this is possible through formation of the fleece itself. Alternatively, the possibility exists of carrying out the expansion process in a restricted volume, e.g. in a double-belt press or in a mold, e.g. for automobile seats. In this way, it is possible to produce specific densities that are technically necessary or desirable. The internal pressure generated by the expansion also presses the long-fiber partial foam system against inner walls of the mold and thus leads to the production of molded parts, e.g. upholstery for automobile seats. Surface layers for decorative or other purposes laid in the mold or double-belt press can thereby be expanded immediately.
[0084] An increase in the strength of the long-fiber partial foam composites can be achieved according to the invention in that the already expanded or subsequently expandable small foam bodies 2 are put as already described into a mixture of natural fibers 1 and polymer fibers 1 . In addition to the nodally disposed bonding of the long fibers 1 through the partial small foam bodies 2 , fusing the polymer fibers 1 at their crossing points using thermobonding can also be used to increase strength.
[0085] If it is necessary to increase the strength and simultaneously reduce the density, a requirement which is becoming increasingly important in automobile construction, it is possible to add to the mixture with the natural fibers 1 , not the polymer fibers 1 according to the state of the art but, instead, such polymer fibers as were expanded (a) already during spinning, or (b) after mixing and nonwoven formation, through the input of energy which activates the foaming agent put into the melt and expands the polymer fiber 1 .
[0086] Partial foam-bonded nonwovens containing mixtures of the natural fibers 1 and the polymer fibers 1 , non-expanded, previously expanded or subsequently expandable, also offer the possibility that if the polymer fibers 1 or the small foam bodies 2 include heat-activatable material, bonding to metal sheets, films, fabric and similar flat materials can take place, if necessary with priming of the flat materials. In this manner, it is possible to fabricate light-weight components of high strength, e.g. automobile doors, passenger vehicle inner linings, sandwich elements of all kinds, and many other objects.
[0087] The above light-weight components can also be fabricated according to the invention as different kinds of sandwich elements if, instead of the use of the polymer fibers 1 , the nonwoven is provided on one or both sides with an adhesive, or a coating of foam, which has an adhesive effect and is able to glue or thermally fuse the nonwoven with flat-shaped structures, e.g. metal sheets, decorative materials and many other objects.
[0088] Fleeces and similar objects fabricated according to the above systems can be thermoformed and subsequently compression molded if any thermoplastic components and/or duromer components they contain are not yet in a cross-linked state. At the same time, different zones of the fleeces can be compressed in the mold to different extents. In the edge zones, for example, highly compressed in order to achieve high strength and stiffness, e.g. for self-supporting parts, and only slightly compressed in the middle region in order to achieve an upholstered effect or for other reasons. According to this process, it is also possible to press ribs or embossing with selectable depth and density into the molded part for purposes of stiffening or decoration. The process is especially suitable for the fabrication of stiff, dimensionally stable and yet lightweight internal fittings for vehicles, which fittings do not splinter in the case of a crash.
[0089] [0089]FIG. 3 shows a cross section through a car door produced using the long-fiber foam composite according to the invention. The automobile door (also referred to as a “car door”) is composed of two separately produced elements: an outer door element 1 . 0 and an inner door element 2 . 0 .
[0090] Each element has different functions and correspondingly different characteristics, and therefore has to be described separately.
[0091] In addition to the known functions of the prior art, the outer door element 1 . 0 is also intended to increase side-impact protection, i.e. high flexural strength and high flexural impact strength, in order to supplement or replace the functioning of the safety cross-members. In addition, the outer door element 1 . 0 provides hip and rib protection in place of foam pads. The outer door element 1 . 0 provide high-performance thermal insulation, which is unavailable in the prior art.
[0092] In order to fulfill the function of side-impact protection, the long-fiber foam composite according to the invention must be built so that the elements produced therefrom have high flexural strength and flexural impact strength, and do not shatter in the event of a crash. These properties can only be generated using longfibers. It is vital that they are felted with one another (i.e. nonwoven) and also adhesive-bonded to one another, so that the high level of mechanical properties mentioned is generated. The skilled worker is aware that the tensile strength of a nonwoven increases as fiber length increases, exactly as is known to be the case for paper, strandboard, and similar materials. Both long fibers and adhesive bonding must be present together if the very high tensile strengths of the long fibers are to be transformed into equally high tensile strength and flexural strength for the elements produced therefrom. According to the invention, only “partial” adhesive bonding is intended to take place by virtue of fluid, highly adhesive binder droplets. The binder droplets can be unfoamed or previously formed. The purpose of the adhesive bonding is to prevent shifting of the individual long fibers with respect to one another in the nonwoven when subjected to force, i.e. to prevent them from being separated.
[0093] In the prior art, hip and rib protection is provided mainly by foam cushions, called pads, inserted into the hollow doors. In the event of a crash, they provide protective cushioning of the hip and rib area. At the same time, their deformation dissipates some of the energy of the impact, preventing it from acting on the body of the accident victim.
[0094] If, according to the invention, binder droplets including blowing agents are introduced between the long fibers during production of the long-fiber foam composite, and are then foamed, the result after curing of the foamed binder droplets is a very dimensionally stable, resilient long-fiber foam composite element. In such a long-fiber foam composite element, the long fibers have been laterally secured and very firmly adhesive-bonded to one another by the foam bodies. In addition, they have also been provided with support from the inside. Since the entire outer door element 1 . 0 is composed of this type of long-fiber foam composite, the result of the extensive lateral tensile bracing is higher compressive strength than that of small-format foam pads. The padding effect is correspondingly more effective in the inventive solution, and the protective action is correspondingly greater.
[0095] The function of the thermal insulation is likewise provided by the long fibers. However, according to the invention it is raised to a considerably higher level by the partial foam bodies. As described above, the actual thermal insulation is provided by the interstitial air between the long fibers. As the skilled worker is aware, the more interstitial air there is the better the thermal insulation. A precondition that must be imposed here is that the air cannot be moved by convection but remains still. Both preconditions are provided by the small foam bodies of the invention:
[0096] Firstly, they push the long fibers apart during the foaming process and thus permit more interstitial air to enter between the long fibers than would be possible using long fibers not supplemented by foamable binder droplets. By virtue of the foamable binder droplets, therefore, the density achieved for the nonwoven is lower than that achievable in the prior art. This raises the thermal insulation value considerably.
[0097] Secondly, the foamed binder droplets have irregularly offset positions transverse to the longitudinal axis of the respective linked long fibers and between these generate a labyrinth that increases the resistance to flow between the fibers. This makes a decisive contribution to preventing easy movement of the air by convection, and therefore to retaining the insulating action of the air.
[0098] Finally, the totality of the system of the invention provides modern automotive construction with the significant additional advantage of achieving high strength and good thermal insulation through measures that at the same time bring about a significant weight reduction of the respective components. he subsequent foaming of the binder droplets adhesive-bonded to the long fibers may be compared with the inflation of an inflatable warehouse. In its semi-inflated condition, it is unstable and oscillates to-and-fro in an uncontrolled manner. In contrast, once it has been fully inflated and its lateral traction cable has been tensioned it becomes rigid and resistant to compression and achieves a dimensional stability that can even resist storms, although the weight of the entire system is only a fraction of that of a conventional warehouse.
[0099] In FIG. 3, the reference number 1 . 0 generally refers to the entire outer door element. The outer skin is formed by the bodywork metal sheet 1 . This sheet has been securely adhesive-bonded via a foamed layer 1 . 2 of a high-strength adhesive to the long-fiber foam composite 1 . 3 to give a sandwich element. The core of the outer door element 1 . 0 is composed of a mixture of long fibers 1 . 4 . For environmental reasons these are mostly natural fibers. To increase strength inter alia by node formation using thermal bonding, and to increase thermoformability, polymer fibers with or without incorporated blowing agents have been admixed. These are partially adhesive-bonded to one another by binder droplets 1 . 5 . After forming of the “long fiber foam composite”, which initially has the form of a mat, and coating of the outer layers with a foamable adhesive, this is cut to size or stamped, inserted into a mold with the metal door panel 1 . 1 , and there foamed with introduction of energy. The result here is that the foaming pressure produced in the interior, depending on the mold volume present at respective locations, leads to establishment of different densities of the nonwoven produced from the long-fiber foam composite preform. The density of the nonwoven at the channels 1 . 6 for cables, door-lock linkages, air ducting, inter alia, and also around the safety cross-members 3 . 0 , is higher, due to the reduced cross section, than in areas where there is no narrowing of cross section.
[0100] The density differences are illustrated by shading in FIG. 3. Light=low density; mid-gray=medium density; black=high density.
[0101] The functions of the inner door element 2 . 0 are different from those of the outer door element. It is intended to be part of the decorative design of the passenger compartment. The inner door element 2 . 0 substantially supplements the side-impact protection provided by the outerdoor element 1 . 0 , and serves as a support for functional elements, following the trend toward the modular construction desired for the future of the automotive construction industry.
[0102] Reference number 2 . 1 denotes the decorative inner side of the element. During the process of compressive molding, it may be attached by adhesion to the nonwoven during the compressive molding process, using the one-shot process, or attached by foaming, or else attached subsequently by adhesion. Reference number 2 . 2 is the adhesive foam layer that also serves to improve feel.
[0103] Decorative materials that may be used are fabrics, films, leather, etc., covering the entire surface or in combination.
[0104] Decorative embossments 2 . 13 are an example of other decorative possibilities for the system.
[0105] In the region of the waistline the nonwoven 2 . 3 produced by foaming pressure provides a medium-density long-fiber foam composite by virtue of the mold volume available at that location. Its medium density gives it sufficient strength to provide the performance characteristics required at that location, but sufficient yielding characteristics to provide cushioning action, and therefore protection of the occupants, in the event of a crash.
[0106] Hip protection, likewise designed at medium density, is illustrated at 2 . 12 . It is intended to replace prior-art foam-only pads for the purpose of improving hip protection. The improved protection is a result of the combination of long fibers and small adhesive-bonding foam bodies providing support from inside. The extensive lateral bracing permits dissipation and damping of the incident impact energy overrun area that is substantially greater than would be permitted by a foam pad, i.e., a trampoline effect.
[0107] A prior-art airbag 2 . 5 serves to protect the ribs. 2 . 4 is the holder to receive the airbag, produced by the process of the invention, during the compressive molding process. For this, the volume of the mold was kept so low as to produce a highly-compacted rear panel made from long fibers and from foamable binders as rear support for the airbag. At densities less than one-thousand kilograms per cubic meter (<1,000 kg/m 3 ), the strength values come close to those of metals. Reference number 2 . 6 denotes a burstable membrane (bought-in component) serving as protective cover for the airbag.
[0108] The trend in the automotive construction industry is toward the modular method of construction. An example of a long-term aim is that a door is delivered fully assembled and then merely requires fitting by the car producer. The intention is that windows, window lifters, lock, lock linkages, remote-closure assembly, lifter motor, loudspeakers, etc. are to be pre-assembled within the module. All of these assemblies require supports to which they can be secured.
[0109] Since in the system of the invention the shape and strength can be adjusted via density, polymer content, thermoset content, it is possible, for example, to combine low-density cushioning subregions with highly compacted, higher-binder-content, and therefore high-strength ribs, linear reinforcement, or high-density subareas. The invention therefore permits production of a highly compacted structural system suitable for accepting the functional elements mentioned and for supporting them within the system of the module. Examples are the box 2 . 10 to receive a loudspeaker 2 . 9 with the protective covering 2 . 11 (third-party supply), the arm rest 2 . 8 (typically supplied by a third-party) with the installation space 2 . 7 in the compression-molded highly compacted cavity 2 . 4 , or the airbag recess 2 . 5 . Alongside the highly-compacted zones shown in the cross section, the invention also permits the production of vertical highly compacted support zones meeting the particular requirements of the individual case.
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A long fiber-foam composite material, in which the long fibers are bonded to form a loose but dimensionally stable structure with good recovery properties. The long fibers are only partially bonded by foam particles in the shape of nodal points. The unfoamed or unfoamed foam particles are inserted into the structure when the latter is being formed. The unfoamed foam particles inserted into the structure are foamed by reacting or reactivating a foaming agent previously applied to a binding agent to be foamed. The expansion can freely take place without limiting the volume so that a minimal possible thickness can be obtained by complete expansion or in a predetermined volume having a predetermined thickness, for instance, by expansion in a double wall press or a mold.
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RELATED APPLICATION
[0001] This application is a divisional application of U.S. patent application Ser. No. 13/666,418 filed Nov. 1, 2012, now allowed, which is a divisional application of U.S. patent application Ser. No. 13/396,852 filed Feb. 15, 2012, now pending, which is a continuation application of U.S. patent application Ser. No. 12/245,116 filed Oct. 3, 2008, now U.S. Pat. No. 8,152,334, which claims priority to U.S. Provisional Patent Application Ser. No. 61/095,159, filed Sep. 8, 2008, the entire content of which is incorporated herein by reference. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND
[0002] Light emitting diodes (“LEDs”) are increasingly being used in applications where incandescent or fluorescent lights had previously being used. There are inground lights that are currently used for various lighting applications such as landscape and outdoor lighting. Typical previously existing inground lights, even those employing LEDs, are not optimized for use of LEDs and concomitant thermal management issue. For, example, these devices can suffer from thermal issues such as poor heat management and heat retention due to, e.g., poor conduction and/or convection. Among other things, such thermal management issues can lead to shortened light service life.
[0003] The issues of aiming inground light assemblies are typically addressed by opening the sealed light structure and then adjusting the base/lighting assembly manually with the unit open, e.g., to the elements and while being susceptible to dirt, water intrusion, etc.
[0004] What is desirable, therefore, are devices and techniques that address such limitations described for the prior art.
SUMMARY
[0005] Embodiments of the present disclosure address the shortcomings previously described for the prior art. Exemplary embodiments of the present disclosure include inground LED lighting units/assemblies that can be aimed by external adjustment devices/features/means without the need to open the sealed LED module. Heat from the LEDs and/or LED mounting assembly can be transferred to the outside air or internal heat conducting structures while the module is tilted, e.g., up to 15 degrees or more, from vertical. Use of materials (e.g., thermally conductive grease and/or bronze alloys) with high thermal conductivity can facilitate thermal management. The thermal dissipation/management afforded by the designs of embodiments according to the present disclosure can allow for an increase of the LED useful service life.
[0006] The sealing of the inground light unit can preclude/minimize the chance of an end user (e.g., service technician) from causing the unit to leak and thereby cause premature failure. Additionally, the modular structure of the inground LED light can allow for upgrade/renewal of associated electronics with only minor disassembly.
[0007] Moreover, embodiments of the present disclosure can provide increased service life for inground modules and/or LEDs in use by superior/improved thermal management, e.g., by the selection and use of thermally conducting materials such as bronze bushings or thermally conductive greaser, and/or the presence of an annular gap (doughnut) between the outer housing and the surrounding concrete/cement, thus providing a desired space/volume for air floor (and convective cooling).
[0008] Other features and advantages of the present disclosure will be understood upon reading and understanding the detailed description of exemplary embodiments, described herein, in conjunction with reference to the drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Aspects of the disclosure may be more fully understood from the following description when read together with the accompanying drawings, which are to be regarded as illustrative in nature, and not as limiting. The drawings are not necessarily to scale, emphasis instead being placed on the principles of the disclosure. In the drawings:
[0010] FIG. 1 depicts various views of an inground LED light, in accordance with exemplary embodiments of the present disclosure;
[0011] FIG. 2 includes FIGS. 2A-2F , which depict a top view and various cross section views, respectively, of an exemplary embodiment of the present disclosure; and
[0012] FIG. 3 is a data sheet for an optic (optical element) used for dispersion/light shaping of light from LEDs in accordance with an exemplary embodiment of the present disclosure.
[0013] While certain embodiments depicted in the drawings, one skilled in the art will appreciate that the embodiments depicted are illustrative and that variations of those shown, as well as other embodiments described herein, may be envisioned and practiced within the scope of the present disclosure.
DETAILED DESCRIPTION
[0014] Embodiments of the present disclosure include lighting modules that can include multiple LEDs in a sealed housing suitable for use in inground applications. The lighting assemblies can be aimed by external adjustment devices/features/means without the need to open the sealed lighting module. The lighting modules additionally are optimized for thermal management of heat produced from the LEDs and related structure(s). For example, by use of heat conducting materials, heat from the LEDs and/or LED mounting assembly can be transferred to the outside air while the module is tilted, e.g., up to 25 degrees, or more, from vertical. The modular structure of the inground LED light assemblies can allow for upgrade/renewal of associated electronics with only minor disassembly. Moreover, the thermal dissipation/management afforded by the designs of embodiments can allow for an increase of the LED useful service life.
[0015] Embodiments of the present disclosure, e.g., inground LED lights and lighting modules, can be used to illuminate a desired area, e.g., including but not limited to, structures such as buildings, signs, landscape materials, flag poles, interior architectural features, product displays, automobiles, etc., and the like. Embodiments of an inground LED light (product) can be pre-cast in concrete, or directly placed in soil, etc. An outer (e.g., rough-in) housing section/portion of the light assemblies can be installed and connected to a conduit system and appropriate power supply/cables, e.g., one with 120 V power of suitable current.
[0016] FIG. 1 includes FIGS. 1A-1D , which depict top, first section, bottom and second section views, respectively, of an inground LED light assembly 100 , in accordance with exemplary embodiments of the present disclosure.
[0017] Referring to FIG. 1A , the light assembly 100 includes a support 110 on which a plurality of LEDs 112 are positioned on a support surface 114 (e.g., a printed circuit board). The support 110 can be received by a first (inner) housing 120 in such a way that the support 110 can be moved to reorient the optical output from the LEDs 112 . As shown the interior surface of housing 120 can have a partially spherical (curved) portion that can mate with a corresponding spherical (curved) portion of the support 110 .
[0018] As shown in FIG. 1B , which shows a section view along cutting plane 1 - 1 in FIG. 1A , the inner housing 120 can be positioned within a second (outer) housing 130 . A driver and/or power supply (driver/power supply) 116 can be positioned within the first housing 120 . A lens 132 can be held by a lens frame 136 , which itself can be held within the second housing 130 , e.g., by suitable fasteners including but not limited to screws 138 as shown. Also, within the second housing a junction box 140 can be present and connected to the driver/power supply 116 of the first housing 120 by suitable wiring and connector 144 .
[0019] FIG. 1C depicts a bottom view of the light assembly 100 , with the second housing 130 , area of the junction box 140 and apertures 150 for electrical connections shown.
[0020] FIG. 1D depicts a cross section view similar to FIG. 1B in which support 110 is shown oriented (e.g., aimed) in a different direction than as shown for FIG. 1B . In the view, the curved (e.g., spherical) outer surface of the support 110 is shown as remaining in contact with the curved (e.g., spherical) surface of the inner housing 120 , while the direction of the optical output (optical axis) of the LEDs 112 are directed at an angle 1 from the longitudinal axis 2 of the light assembly 100 . To facilitate optimal heat transfer characteristics, thermally conductive grease may be used between the spherical surface of the support 110 and the corresponding spherical surface of the first (inner) housing 120 . As shown, in FIG. 1 , the driver/power supply 116 (which can be encapsulated in epoxy or other materials as desired) can be located as desired in the assembly, e.g., adjacent to a wall of the inner housing 120 . It should be noted that the driver/power supply 116 can be implemented on a two-sided circuit board with alternate circuits/features selectable on each of the two sides. Such two-sided functionality can allow the same driver/power supply 116 board to be used for multiple applications (potentially reducing manufacturing costs). The driver/power supply 116 can be placed in other locations, as for example the embodiment shown and described for FIG. 2 .
[0021] FIG. 2 includes FIGS. 2A-2F , which depict a top view and various cross section views, respectively, of an exemplary embodiment of a lighting assembly (or device) 200 according to the present disclosure.
[0022] FIG. 2A depicts a top view of an inground light assembly 200 . In the top view shown, a housing 230 receives a lens frame 234 that holds a lens 232 . The lens functions to pass light from a number of light sources (e.g., LEDs) located within the device 200 . As will be described in greater detail below, the light sources (not shown in FIG. 2A ) can be supported on a support (module) that is held by another housing in such a way that the orientation of the support is adjustable (or aimable) by an adjustment assembly (or equivalently, a means for adjusting). A representative aiming (orientation) adjustment screw 250 is shown in FIG. 2A .
[0023] FIG. 2B depicts a cross section view of light assembly 200 along section line 1 - 1 . Support 210 is configured and arranged to support one or more LEDs 212 on a supporting surface (e.g., printed circuit board) 214 . Corresponding optics/optical elements 216 can be present. The support 210 (alternatively called “support module” 210 ) can be received by a first (inner) housing 220 in such a way that the support 210 can be moved to reorient the optical output from the LEDs 212 . As shown the interior surface of housing 220 can have a partially spherical (curved) portion that can mate with a corresponding outer spherical (curved) portion of the support 210 . An adjustment assembly/means (e.g., as shown in FIG. 2E ) can be present to reorient the support and LEDs without the need of disassembly of the light assembly 200 . As with the embodiment of FIG. 1 , to facilitate optimal heat transfer characteristics, thermally conductive grease may be used between the spherical surface of the support 210 and the corresponding spherical surface of the first (inner) housing 220 .
[0024] FIG. 2D depicts a cross section view of light assembly 200 along section line 3 - 3 , in which the section details of an adjustment assembly/means are visible. Included are an aiming adjustment screw 250 , wormgear 252 , and wormgear retainer pin 258 . Pivots (e.g., pivot screws) 260 are shown, which allow the support module 210 to rotate about an axis (between the two screws). In alternate embodiments, the support module 210 can be aimed over a solid angle for increased illumination area coverage; for such, solid angle adjustment, the inner housing 220 can be rotatable (about the longitudinal axis of the outer housing). Alternately, the support module can be rotatable (about the longitudinal axis of the outer housing) in which can an alternate adjustment means/assembly 250 would be required. In exemplary embodiments, a second pair of pivot screws configured with an intermediate housing or housing portion between the inner 220 and outer 230 housings could be utilized so as to provide a functional gimbal for aiming the support module (with the light optical axis) over a solid angle. The intermediate housing could have an inner and outer curved (e.g., spherical surface) to mate with the corresponding surfaces of the inner 220 and outer 230 housings.
[0025] FIG. 2D depicts a cross section view of light assembly 200 along section line 3 - 3 , in which the section details of an adjustment assembly/means are visible. Included are an aiming adjustment screw 250 , wormgear 252 , and wormgear retainer pin 258 . Pivots (e.g., pivot screws) 260 are shown, which allow the support module 210 to rotate about an axis (between the two screws). In alternate embodiments, the support module 210 can be aimed over a solid angle for increased illumination area coverage; for such, solid angle adjustment, the inner housing 220 can be rotatable (about the longitudinal axis of the outer housing). Alternately, the support module can be rotatable (about the longitudinal axis of the outer housing) in which can an alternate adjustment means/assembly would be required. In exemplary embodiments, a second pair of pivot screws configured with an intermediate housing or housing portion between the inner housing 220 and outer housing 230 could be utilized so as to provide a functional gimbal for aiming the support module (with the light optical axis) over a solid angle. The intermediate housing could have an inner and outer curved (e.g., spherical surface) to mate with the corresponding surfaces of the inner 220 and outer 230 housings.
[0026] FIG. 2F depicts a cross section view of light assembly 200 along section line 5 - 5 . FIG. 2F shows the wormgear 252 from another perspective.
[0027] In exemplary embodiments, as indicated in FIG. 2 , a housing (a/k/a a finishing section) of the lighting housing, containing a LED support (e.g., which may be referred to as a “SSL19” in reference to solid state lighting employing 19 LEDs), can be connected via a suitable connection, e.g., IP67 submersible connector and placed into an outer housing (rough-in housing, or “RIH”) as pre-cast in concrete. Suitable connectors of desired number and type, e.g., three screws, can connect the outer housing to the RIH. The LEDs of the unit/assembly can then be aimed in a desired orientation/direction, e.g., by rotating an adjustment screw/knob with a suitable tool such as a screw driver or Allen wrench, or manually.
[0028] In exemplary embodiments of device 200 , the LEDs can be Nichia NS6 white LEDs (see, e.g., FIG. 3 ) configured to nominally operate on 350 mA, the lens frame can be made of bronze alloy, the optics can be made of molded acrylic, the lens can be made of low-iron tempered glass, the lens gasket can be made of molded silicon, the second (outer) housing can be made of SMC polyester composite, the support 210 can be made of bronze alloy (e.g., with 5-15% copper), the seal 246 can be a gland type cord seal, the driver/power supply can be encapsulate din an epoxy encapsulant, the gasket 248 can be made from die cut silicon, the cover for the junction box can be made of RIH SMC polyester composite, the inner housing 220 can be made of bronze alloy, and gasket 238 can be made of die cut silicon. It should be noted that all materials indicated for the drawings are examples that may be used for exemplary embodiments; other materials may be used within the scope of the present disclosure.
[0029] With continued reference to FIG. 2 , cross section views of the shape of a number of optics/optical element 216 of a suitable material, e.g., clear acrylic or PMMA, are shown in FIGS. 2B-2D . One skilled in the art will appreciate, however, that other shapes and configurations of the optics 216 may also (or in the alternative) be used, e.g., any type of suitable cross section, such as spherical, hyperbolic, parabolic, combinations of such, etc.; moreover, reflective elements could also (or in the alternative) be used for guiding light away from the one or more LEDs 212 .
[0030] FIG. 3 is a data sheet for an exemplary embodiment of an optic (optical element) used for dispersion/light shaping of LEDs (e.g., as shown by 216 in FIG. 2 ) in accordance with the present disclosure. As used herein the optic/optical element may be referred to by the part number “SAC-002,” though this is merely for convenience.
[0031] Accordingly, embodiments of the present disclosure can provide one or more advantages relative to prior inground lighting apparatus and techniques. For example, embodiments can provide equivalent performance to prior 39 Watt metal halide lamps in 15 fixed spot or 60 fixed flood distribution options. Embodiments may provide for 180 rotation of beam and/or 0-15 tilt angle from vertical.
[0032] Further, exemplary embodiments can provide equivalent performance to 100 W Metal Halide lamps with 10-25 variable spot, 30-60 variable flood, asymmetric wall wash (“AWW”), and/or superior wall wash (“SPW”) distribution options. Exemplary embodiments may provide up to 360 rotation of beam (or multiple rotations), and/or 0-25 (or more) tilt angle from vertical. Furthermore, tilt and rotation can be adjustable without the need to open any housing. And, embodiments can offer the ability to aim the LEDs (and resulting beam) without a main power supply being on. Any suitable LEDs can be used for embodiments according to the present disclosure. Such can include, but are not limited to, LEDs have a color temperature over a range from about 3000 to 6000 degrees K, e.g., 5000 degrees K. Each electrical component/part of devices/assemblies described herein can be water-proofed or sealed to prevent damage by water/moisture or other liquids.
[0033] While certain embodiments have been described herein, it will be understood by one skilled in the art that the methods, systems, and apparatus of the present disclosure may be embodied in other specific forms without departing from the spirit thereof.
[0034] Accordingly, the embodiments described herein, and as claimed in the attached claims, are to be considered in all respects as illustrative of the present disclosure and not restrictive.
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A lighting device having a support module supporting LEDs and having an outer perimeter defining a curved portion, and a housing with an inner surface having a curved portion configured to receive the curved portion of the support module to enable the disk to be aimed, while the curved portions of the disk and housing remain in contact. Optional adjustment means facilitate aiming of the support module without the need to open the sealed LED module.
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BACKGROUND
The present invention relates to an improved tubing hanger and running tool which overcomes the disadvantages of the prior subsea hanger running tools.
Running tools are typically designed to support the weight of a tubing hanger and its associated tubing string during tubing installation on a subsea well completion. In prior devices which are hydraulically operated, difficulties are encountered through a loss of the hydraulic system. This is particularly true since the hydrostatic fluid pressure is very substantial in subsea environments and can exert very substantial pressures on the exposed piston surfaces of the running tool. Some prior running tools were provided with a separate umbilical to ensure that the desired hydraulic pressure could be maintained to avoid the pressure responsive latching means from responding to the substantial hydrostatic pressures encountered at the subsea location. Since it is desired to maintain the running tool in latched engagement with the hanger after the hanger is landed until downhole work is completed, the release of the running tool from the hanger should be possible even when hydraulic latch pressure is lost prior to release. Some prior tools have solved this problem by closing a blowout preventer on the running tool string and then applying pressure through the choke or kill line of the BOP stack. This pressure surrounds the running tool and will cause the latch actuating sleeve of the running tool to retract to its unlatched position allowing retrieval of the running tool.
It is also possible with prior devices that as a result of needing to maintain the hydraulic latch pressure to resist the action of the hydrostatic pressure, the loss of the hydraulic latch pressure during the running of the tubing can result in the unlatching of the running tool. A further disadvantage of those prior tools which have separate umbilicals to the surface is that the umbilical control line is at risk during the lowering from the surface.
U.S. Pat. No. 3,693,714 discloses a tubing hanger with a running tool which uses pressure of hydraulic fluid delivered through the running string and relies on either a locking dart to direct the hydraulic pressure to urge the locking sleeve in the locked direction and an unlocking dart to direct the hydraulic pressure to urge the locking sleeve in the unlocked direction.
U.S. Pat. No. 4,262,748 discloses a hanger and running tool which is secured to the hanger by spring loaded segments and releasing ring on the hanger which on full seating of the hanger cams the segments out of engagement with the hanger to release the running tool therefrom.
U.S. Pat. No. 4,067,388 discloses a running tool and a casing hanger with a split latch ring having external threads which are engaged within the internal hanger threads and a piston ring which wedges the split latch ring into latching engagement with the hanger. Release is either by retraction of the piston ring or by rotation to thread the latch ring out of engagement with the hanger.
U.S. Pat. No. 4,712,621 discloses a casing hanger running tool which is moved between running, setting, releasing and dumping positions. Also, there is a hydraulic system to control a piston which moves latching dogs supporting the hanger on the running tool. Hydraulic fluid is delivered through the bore of the tool.
U.S. Pat. No. 4,736,799 discloses a running tool which is operated by hydraulic fluid delivered through control passages to lower, land, set seal and release from the hanger. A spool valve is provided in the hydraulic system to allow for failure in the release line.
SUMMARY
An improved subsea tubing hanger having a body with an external shoulder for landing on a seat within a subsea wellhead housing, locking means carried by the hanger to engage the housing to lock the hanger in landed position, with the locking means including a locking element, actuating means for setting the locking element and securing means for holding the actuating means in its locked position but being releasable responsive to sufficient upward force to sever the securing means. The improved tubing hanger running tool includes a body supporting a latching means which is hydraulically actuated for engaging a tubing hanger which maintains its latching engagement with the tubing hanger even when the hydraulic connection to the actuating means is lost with hydrostatic riser pressure being exerted on a portion of the actuating means over a larger area than the area which is exposed to the well bore hydrostatic head, a locking mechanism for securing the hanger within the wellhead housing and an emergency latch release available to allow release of the tool from the hanger by the simple expedient of closing the blowout preventer and pressuring the well bore below the blowout preventer to provide a release of the latching of the tool to the hanger.
An object of the present invention is to provide an improved tool for lowering, landing and locking a hanger through a riser to a position within a subsea wellhead housing which remains latched to the hanger despite the loss of hydraulic fluid to the latching side of the actuating means.
Another object of the present invention is to provide an improved running tool for a hanger to be lowered through a riser to a position within a subsea wellhead which can be unlatched from the hanger through an emergency system independent of the hydraulic actuator for the latching mechanism.
Still another object is to provide an improved hanger and running tool for lowering the hanger through a riser to a position within a subsea wellhead housing in which engagement between the hanger and tool is maintained even through hydraulic communication to the latching actuator is lost and can be unlatched without the use of such hydraulic communication.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention are hereinafter set forth and explained with reference to wherein:
FIG. 1 is a sectional view of a subsea wellhead with the improved running tool and hanger of the present invention being run therein, the running tool and hanger being shown in elevation.
FIG. 2A, 2B and 2C quarter sectional views of the improved running tool and hanger being lowered in the subsea wellhead prior to landing therein with FIG. 2A being the upper portion, FIG. 2B being the intermediate portion and FIG. 2C being the lower portion thereof.
FIG. 2D is an enlarged sectional view of the lock test cartridge positioned within the running tool.
FIGS. 3A, 3B and 3C are the upper, intermediate and lower portions of the quarter sectional view of the running tool and hanger landed and locked within the wellhead.
FIGS. 4A, 4B and 4C are the upper, intermediate and lower portions of the quarter sectional view of the running tool and hanger showing the hanger locked in its landed position within the wellhead and the running tool released therefrom and being retrieved.
FIG. 5A, 5B and 5C are the upper, intermediate and lower portions of the quarter sectional view of the running tool, hanger and wellhead showing the hanger locked in its landed position within the wellhead and the running tool emergency release being activated.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, subsea tubing hanger H is supported from running tool T and being lowered through riser R into the interior of subsea wellhead W. Wellhead W includes wellhead housing 10 having internal landing seat 12 therein for receiving shoulder 14 of hanger H, blowout preventer stack 16 secured above housing 10 by collet connector C and riser R secured above blowout preventer stack 16. Riser R extends to a suitable structure (not shown) at the surface for the drilling and other operation within wellhead W. Running tool T is suitably latched to hanger H and is lowered as shown into position for landing on shoulder 14. When landed as herein after described, hanger H is locked in its landed position and running tool T is left in engagement therewith until it is to be withdrawn.
Running tool T and hanger H are shown in FIGS. 2A, 2B and 2C as quarter sectional views. The sectional views of hanger H and running tool T in FIGS. 2 through 5 are distorted sectional views to show the hydraulic passages as though they were radially positioned but they are suitably positioned in tool T and hanger H both radially and circumferentially to accommodate their function and coaction.
Hanger H includes body 18 having suitable passages 20 with only one of such passages being shown and external landing shoulder 14 which is sized to allow hanger H to land and be seated on internal landing seat 12 within wellhead housing W. Locking ring 22 is positioned in surrounding relationship to the lower portion of hanger body 18 at a position spaced above landing shoulder 14. Sleeve 24, which is secured to body 18, defines an annular slot 26 in which split locking ring 22 is positioned and is secured to body 18 by suitable means, such as set screws 28. Lock actuating sleeve 30 is positioned in surrounding and slidable relationship around body 18 and within sleeve 24. Actuating sleeve 30 includes slots 32 through which cap screws 28 extend to allow axial movement of sleeve 30 with respect to body 18, sleeve 30 and locking ring 22. The lower end of actuating sleeve 30 includes taper 34 which coacts with the upper interior surface 36 of locking ring 22 so that downward movement of actuating sleeve 30 moves its taper 34 under locking ring 22 and wedges locking ring 22 radially outward into locking engagement within annular locking recess 38 in the interior of housing 10 to lock hanger H therein.
The locking of hanger H into housing 10 is responsive to pressure delivered through passage 40 to the upper side of lock piston 42 while pressure from the lower side of lock piston 42 is vented through passage 44. Lock sleeve 46 is threaded onto lock piston 42 and extends downwardly so that its lower end engages hanger lock sleeve 48. Orienting pins 50 are positioned in slots 52 and engage within tool body 54. Orienting key 56 is secured to hanger body 18 by screw 58 and is adapted to coact with orienting sleeve 60 which is positioned within well housing 10 to ensure that the proper location of well components lowered therein are duplicated so that the tubing connections will be properly aligned with passages 20. Lock piston 42 is suitably connected to actuating sleeve 30 as hereinafter described to ensure proper locking of hanger H within housing 10 when it has been properly landed therein.
During running of hanger H as shown in FIGS. 1, 2A, 2B and 2C, tool T is securely engaged to hanger H. This engagement is provided by the engagement of split latch ring 62 within internal latching groove 64 on the interior of hanger sleeve 66. This latching is done at the surface and is accomplished by supplying hydraulic pressure to latch passage 68 and venting unlatch passage 70 which passages extend through tool body 54 and are provided with suitable connections to the surface through running string 72 while string 72 is connected to the upper end of tool body 54. The connecting means for making this connection include ring 74 which includes a bore so that it fits around the upper exterior of tool body 54 and is threaded thereon with its upper end being in engagement with downwardly facing shoulder 76. Flange 78 extends outwardly from the central portion of the exterior of ring 74 and suitable seals are provided to seal against the exteriors of string 72 and tool body 54. Lock nut 80 is threaded on the upper exterior of ring 74 and has its inner downwardly facing shoulder 82 in engagement with external upwardly facing shoulder 84 on the exterior of string 72 to secure this connection. Suitable seal is provided around the lower exterior of ring 74 for sealing against the interior of upper rim 86 of lock piston 42. This structure provides the upper lock chamber 88 to which passage 40 communicates and unlock chamber 90 to which passage 44 communicates. Thus, pressure through passage 40 causes lock piston 42 to be moved downwardly and pressure through passage 44 causes lock piston 42 to be moved upwardly.
Latch piston 92 is positioned below upper stop ring 94 which forms the lower end of unlock chamber 90 and lower stop ring 96 with split ring 98 engaging in external groove 100 in the exterior of tool body 54 and screws 102 extending through the upper portion of lower stop ring 96 to secure ring 98 in groove 100 and to secure lower stop ring 96 in position immediately below upper ring 94. Lower stop ring 96 includes lower outer rim 104 which is spaced outward from the exterior of tool body 54 and receives upper rim 106 of latch piston 92 with chamber 108 which is vented to the interior of riser R through passage 110 so that on closing of either of the ram-type blowout preventers of blowout preventer stack 16 internal riser pressure is above the closed preventer is communicated to chamber 108.
Latch chamber 112 is formed above the seals in the exterior of latch piston flange 114 and between the seals against the interior of latch piston 92 between passages 68 and 70. Unlatch chamber 116 is formed below the seal in the exterior of latch piston flange 114 and above the seals engaging lower piston rim 118. The effective pressure area of riser vent chamber 108 is larger than the effective pressure area of the lower portion of latch piston rim 118 below the inner and outer seals. Since the annulus pressure from below hanger may be exerted on this lower piston rim area, the larger pressure induced force of riser vent chamber 108 allows the lowering of tool T with hanger H thereon without the necessity of maintaining latching pressure on latch chamber 112. This is a very substantial advantage since it is possible to lose communication to the hydraulic passages in tool T during operations and as with prior tool such loss could act to unlatch the engagement between the tool and hanger, the prevention of this unlatching avoids problems which could arise if there were an unlatching of the engagement.
During the latching movement of piston 92, piston 92 moves downward and through its connection to sleeve 120 causes the lower end of sleeve 120 which functions as latch actuator 122 to be moved downwardly under latch ring 62 causing it to be wedged outwardly into latching engagement within internal latching groove 64. This secures tool T to hanger H. Unlatching is accomplished by supplying hydraulic fluid to unlatch chamber 116 through passage 70 and with latch chamber 112 being vented through passage 68. This moves latch piston 92 upwardly causing latch actuator 122 to be raised and moved out from within latch ring 62 so that latch ring 62 contracts inwardly out of engagement with internal latching groove 64 to cause tool T to be unlatched from hanger H.
Lock sleeve 46 is connected to hanger lock sleeve 48 by dogs 124 which have an upper enlargement 126 engaged within recess 128 on the interior of lock sleeve 46 and lower enlargement 129 engaged within recess 130 on the interior of hanger lock sleeve 48. The interior of hanger lock sleeve 48 also includes internal projection 132 below recess 130 which in the running position is engagement with projection 134 on the exterior of guard ring 136 which is secured by cartridge valve 138 to tool body 54. Cartridge valve 138, as best seen in FIG. 2D, is secured within tool body 54 and is positioned to be aligned with internal projection 132 when hanger locking means has been set to locked position with lock ring 22 secured within recess 38. Cartridge valve 138 includes body 140 which is threaded within recess 142 in tool body 54 with an internal inwardly facing seat 144 to coact with valve member 146 positioned within body 142 and biased outwardly by spring 148 to have external shoulder 150 in engagement with seat 144 to prevent flow therethrough. The outer portion of valve member 146 includes cap 152 which is adapted to engage projection 132 when locking has been completed. Passage 156 communicates through tool body 54 to the inner end of recess 142. Passage 154 communicates through tool body 54 with recess 142 at a position above seat 144. Body 140 includes external groove 158 in communication with passage 154 and by-pass 160 extending through body to communicate with passage 162 which extends to the lower end of tool body 54.
With hanger H and tool T assembled as shown in FIGS. 1, 2A, 2B and 2C, the assembly is lowered into the wellhead W as shown. Key 56 will engage the mule shoe or helical taper in orienting sleeve 60 to cause hanger H and tool T to rotate to the desired orientation and then further downward movement causes hanger shoulder 14 to come into engagement with landing seat 12 within housing 10. With landing determined, hydraulic pressure is supplied through lock passage 40 and passage 44 is vented. This causes lock piston 42 to be moved downwardly, which moves lock sleeve 46, hanger lock sleeve 48 and actuating sleeve 30 to also move downwardly. This moves the lower tapered end of actuating sleeve 30 within lock ring 22 to force it outwardly into locking engagement within recess 38 on the interior of housing 10 to function as the locking means locking hanger H within housing 10. In this position any operations which need to be conducted may be completed without fear of unlatching the engagement of tool T from hanger H even though such operations may result in the interruption of the delivery of hydraulic pressure through passage 68 to latch chamber 112. This is because riser vent chamber 108 has a larger effective pressure area than effective pressure on the lower portion of latch piston 92. This latched and locked position of the assembly is clearly illustrated in FIGS. 3A, 3B and 3C.
It should be noted that the supplying of pressure through lock test passage 156 will provide an indication of the successful locking of the locking means within housing 10. This is indicated by an increase flow in the return of fluid through vent passage 154. Further, the depletion of fluid pressure in passage 156 could be used as a further indication of the successful locking which positively indicates that projection 132 on the interior of hanger sleeve 48 has moved downwardly and engaged cap 152 of lock test cartridge valve 138 to unseat valve member 146 from engagement with seat 144, thus providing communication through cartridge valve 138 between passages 156 and 154.
When such operations are complete and it is desired to retrieve tool T, hydraulic pressure is supplied through unlatch passage 70 and latch passage 68 is vented. This causes latch piston 92 to move upwardly resulting in the upward movement of latch actuator 120 to allow latch ring 62 to withdraw inward out of engagement with latching groove 64. This upward movement also allows lower enlargement 129 on dogs 124 to move inward onto the lower end of sleeve 120 and out of engagement with recess 130 on the interior of hanger lock sleeve 48. This completes the disengagement of tool T from hanger H and lifting on string 72 allows the recovery of tool T from within the wellhead W. It should be noted that if the hanger is to be retrieved for any reason, the locking can be reversed by reversing the pressure of the hydraulic fluid and cause the unlocking of the locking means. This allows the assembly to be retrieved. After replacement of the shear pins 168 it can be run and locked.
Tubing element 164 is positioned in the tubing string passage 166 within the lower end of tool body 54 and also within passage 20 in the upper end of hanger body 18. Suitable seals are provided around the exterior of tubing element 164 and its inner diameter is substantially the same as the diameter of passages 166 and 20 so that there is no appreciable restriction of the tubing string in passing through tool T and hanger H.
The normal unlatching and recovery of tool T from hanger H is illustrated in FIGS. 4A, 4B and 4C and the emergency unlocking of hanger H from housing 10 is illustrated in FIGS. 5A, 5B and 5C. An alternate mechanical unlocking of hanger H is provided by a separate tool (not shown) which exerts sufficient pull on a string carrying the tool which engages hanger H to sever shear pins 168. Shear pins 168 are normally held within recesses 170 on the exterior of hanger body 18 and are biased outwardly by springs 172. During all operations pins 168 are held within recesses 170 by engagement with the inner surface of actuating sleeve 30. Actuating sleeve 30 includes inserts 174 each having an inwardly facing recess 176 of sufficient size to receive the outer end of one of pins 168 and positioned to allow pins 168 to move therein when sleeve 30 has moved to its lowermost or locked position. Conversely, once hanger H has been properly locked to housing 10, it may be release by exerting sufficient tension on the string 72 to shear pins 168. Upon shearing of pins 168, actuating sleeve 30 can then be moved upwardly by the lifting and this unlocks the locking means by cause locking ring 22 to withdraw from its engagement within recess 38. The emergency unlocking and recovery of hanger H may be utilized while tool T is still latched to hanger H or it may be utilized when tool T is rerun and latched into hanger H. On the rerunning of tool T it is suggested that suitable orienting means (not shown) be provided and such means can be secured to tool T by screws engaging within orienting pins 50.
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An improved subsea tubing hanger having a body with an external shoulder for landing on a seat within a subsea wellhead housing, locking means carried by the hanger to engage the housing to lock the hanger in landed position, which locking means includes a locking element, actuator for setting the locking element and a securing pin for holding the actuating means in its locked position but being releasable responsive to sufficient upward force to sever the securing pin. The improved running tool includes a body with hydraulic actuated latching means for engaging the tubing hanger and which maintains its engagement with the tubing hanger even when hydraulic pressure is lost. The actuator includes an area exposed to hydrostatic riser pressure with sufficient area to retain the actuator in latched position even through the remainder of the actuating means is exposed to well bore hydrostatic head urging it out of latched position.
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This application is a Continuation of U.S. application Ser. 08/377,391,filed Jan. 24, 1995, which is a continuation-in-part of U.S. patent application Ser. No. 08/186,811 filed Jan. 24, 1994 now U.S. Pat. No. 5,484,705.
BACKGROUND OF THE INVENTION
The present invention relates to methods for determination of the presence of Lipopolysaccharide binding protein (LBP) in body fluid samples including blood samples.
Lipopolysaccharide (LPS) is a common component of the outer membrane of Gram-negative bacteria and is responsible for many of the pathologic effects associated with gram-negative bacterial infection and endotoxemia. Because of the association between bacterial infection and sepsis, attempts have been made to correlate serum/plasma levels of endotoxin with disease. Typically, endotoxin levels have been measured using the Limulus amebocyte lysate (LAL) assay, in which endotoxin initiates a coagulation cascade that can be measured physically, turbidimetrically, or spectrophotometrically, Despite these attempts, however, no reliable correlations between endotoxin levels and sepsis severity or outcome have been identified. This is most likely due to the fact that (i) endotoxin levels in septic patients are very low (>10 pg/L), several serum proteins interfere with the proteolytic LAL cascade, (iii) endotoxin, once in contact with blood, can be “detoxified” by interaction with a variety of blood components, including high-density lipoprotein (HDL) and low-density lipoprotein (LDL) and (iv) endotoxin from different gram-negative organisms varies in its ability to trigger the LAL cascade. Thus, the absolute levels of endotoxin in a patient sample may not correspond to the actual concentrations of bioactive endotoxin present in vivo.
Two related proteins have been identified in humans and other animals that bind LPS with high affinity. These two proteins, Lipopolysaccharide binding protein (LBP), and bactericidal/permeability increasing protein (BPI) have roughly the same molecular weight and share 45% amino acid homology, yet exhibit distinct physiological differences. LBP is a 60 kD glycoprotein synthesized in the liver, while BPI is found in the azurophilic granules of neutophils. LBP is found in the semen of normal humans at levels of 5-10 μg/mL but can reach levels of 5-100 μg/mL in septic patients. Schumann et al., Science , 249:1429 (1990) disclose the amino acid sequences and encoding cDNA of both human and rabbit LBP. Like BPI, LBP has a binding site for lipid A and binds to the LPS from rough (R-) and smooth (S-) form bacteria. Unlike BPI, LBP does not possess significant bactericidal activity. BPI has been observed to neutralize and inhibit the production of TNF resulting from interaction of LBP with LPS and CD14 on monocytes and macrophages. Marra et al., J. Immunol . 148: 532 (1992), Weiss et al., J. Clin. Invest . 90: 1122 (1992). In contrast, LBP is observed to enhance LPS-induced TNF production. Wright et al., Science , 249:1131 (1990). Thus, in contrast to BPI, LBP has been recognized as an immunostimulatory molecule. See, e.g., Seilhamer, PCT International Application WO 93/06228 which discloses a variant form of LBP which it terms LBP-β. Also of interest to the present invention are Ulevitch, PCT International Application WO 91/01639 which discloses, among other things, anti-LBP antibodies as an anti-sepsis therapeutic agent and U.S. Pat. No. 5,245,013 which relates to LBP and discloses antibodies which immunoreact with a polypeptide having homology to LBP.
LBP has been characterized in the art as an “acute phase protein”, that is one of many plasma proteins (such as C-reactive protein, fibrinogen and serum amyloid A) that increase in concentration in response to infectious and non-infectious tissue destructive processes. As such, it would be anticipated that LBP levels would be elevated in samples from patients suffering from a number of autoimmune diseases such as rheumatoid arthritis and lupus erythematosus.
Of interest to the present invention are disclosures related to the assaying of BPI activity in subjects. von der Mohien et al., Abstract, 13th International Symposium on Intensive Care and Emergency Medicine, Brussels (March 1993) discloses the results of assays for serum levels of BPI in patients with gram-negative sepsis and healthy subjects. The abstract disclosed that no BPI was detectable under the conditions of the assay in the serum of healthy subjects while circulating BPI was detected in all septic patients. Also of interest is the disclosure of co-owned and copending U.S. patent application Ser. No. 08/175,276 filed Dec. 29, 1993 which is a continuation-in-part of application 08/125,677 filed Sep. 22, 1993, now U.S. Pat. No. 5,466,581 the disclosures of which are hereby incorporated by reference. Those patent applications disclose that levels of BPI in blood plasma samples correlate with the presence or absence of sepsis while levels of BPI in blood serum samples do not. The patent applications teach that levels of BPI present in serum are not representative of endogenous extracellular levels of BPI in circulating blood while levels of BPI in plasma are.
Also of interest to the present invention are the disclosures of leturcq et al., Keystone Tahoe Endotoxin Conference, Mar., 1-7, 1992 (Abstract) in which the generation of monoclonal antibodies to human LBP is reported. Also reported is the screening of normal human serum samples for the presence of LBP. LBP levels for normal serum samples were reported to range from 1 μg/mL to 24 μg/mL with an average of 7 μg/mL. Further of interest is the disclosure of Richard Ulevitch at the American Society for Microbiology General Meeting in Atlanta, Ga. May 16-21 (1993) at which data was presented on LBP and soluble CD14 levels in the serum of septic and healthy individuals. The average soluble CD14 and LBP concentrations in the serum of healthy adults were 1 μg/mL and 7 μg/mL respectively. The average soluble CD14 and LBP concentrations in the serum of septic patients were reported to be 2 μg/mL and 55 μg/mL respectively.
Geller et al., Arch. Surg ., 128: 22-28 (1993) disclose experiments in which the induction of LBP mRNA was studied in three models known to induce acute phase responses: (1) LPS injection; (2) Corynebacteriun parvum injection; and (3) turpentine injection. The publication reports that LBP mRNA is induced during hepatic inflammation and suggest that LBP is an acute-phase protein important in regulating the in vivo response to endotoxin.
Gallay et al., Infect. Immun ., 61:378-383 (1993) disclose that an acute phase response in mice injected with silver nitrate induced LBP synthesis, and that LBP levels increase approximately 10-fold over normal levels after an acute-phase response.
The exists a desire in the art for methods for determining the exposure of subjects to endotoxin and for distinguishing the effects of exposure to endotoxin from other acute phase physiologic responses. Also desired are methods for diagnosing the presence or severity of gram-negative sepsis in a subject and for predicting the prognosis of a subject suffering from sepsis.
SUMMARY OF THE INVENTION
The present invention provides methods for determining exposure of a subject to endotoxin by assaying for LBP. The invention further provides methods for screening for exposure to gram-negative bacterial endotoxin in an acute phase response in humans by assaying for LBP. Specifically, the method comprises the steps of determining the concentration of LBP in a sample of body fluid from the subject and correlating the concentration of LBP with a standard indicative of the exposure to endotoxin. Such standards can include a subjective standard for a given subject determined by LBP levels of that subject in a pretreatment state such as prior to undergoing surgery. Exposure to endotoxin as a consequence of such surgery can be determined by comparing post-surgical LBP levels with the standard established prior to surgery for that subject. Where access to a pretreatment standard level of LBP is not available for a given individual, objective standards based upon population or subpopulation averages may be applied for comparison. One such standard can be a concentration greater than approximately 15 μg/mL in human plasma or serum, as determined herein for LBP values in subjects suffering from numerous disease states. Subjects exhibiting LBP levels above that standard could presumptively be diagnosed as suffering from exposure to endotoxin while those having levels below that standard would not be. It is clear that alternative standards could be established depending upon the desired sensitivity and selectivity of an assay method and upon the subpopulation in which a given subject falls. For example, standards might be established at different levels for different ages, genders, ethnicities and underlying health conditions of various subpopulations. Moreover, it should be understood that standard levels will differ according to the identity of the particular body fluid which is assayed.
The invention furtherprovides methods for diagnosing the presence or severity of sepsis in a subject comprising the steps of determining the concentration of LBP in a sample of body fluid from the subject and correlating the concentration of LBP with a standard indicative of the presence or severity of sepsis. The invention further provides methods for predicting the prognosis of a subject suffering from sepsis comprising the steps of determining the concentration of LBP in a sample of body fluid from the subject and correlating the concentration of LBP with a standard indicative of the prognosis of a subject suffering from sepsis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the dose-response curves for rLBP, rLBP 25 , rBPI and rBPI 23 in LBP sandwich assays;
FIG. 2 depicts LBP levels (mean±standard error) in the plasma of healthy human subjects and human subjects suffering from various disease states;
FIG. 3 depicts LBP levels (mean±standard error) in healthy subjects treated with LPS;
FIG. 4 depicts comparative survival in suspected gram-negative sepsis patients classified as having either high or low levels of plasma LBP; and
FIGS. 5 a , 5 b and 5 c depict LBP, C-reactive protein (CRP) and fibrinogen levels (mean±standard error), respectively in healthy, rheumatoid arthritic and septic subjects.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to methods for quantifying the presence of LBP in body fluids including blood. While the assay can be used to determine the presence and quantity of LBP which has been administered therapeutically, it is particularly useful for quantifying the presence of endogenous LBP in circulating blood as an indication of exposure of a subject to endotoxin. Moreover, quantifying the presence of LBP is contemplated to be useful in diagnostic and prognostic methods for evaluating gram-negative sepsis patients.
The present invention provides a sandwich ELISA assay for human LBP which exhibits high assay sensitivity, high specificity, and excellent reproducibility. As used herein “LBP” quantitated according to assay methods includes native LBP, recombinant LBP, LBP fragments and analogs as well as other LBP proteins and protein products.
The amino acid and nucleotide sequence of recombinant LBP are set out in co-owned and copending U.S. patent application Ser. No. 08/029,510 filed Jun. 17, 1993 as shown in SEQ ID NOS: 1 and 2 herein. A recombinant LBP amino-terminal fragnent is chracterizd by the amino acid sequence of the first 197 amino acids of the amino-terminus of LBP as set out in SEQ ID NOS: 3 and 4 the production of which is described in co-owned and copending U.S. patent application Ser. No. 08/079,510 filed Jun. 12, 1993 the disclosure of which is incorporated herein. Such LBP protein products may be readily quantified using assays including immunological assays and bioassays in the subnanogram per mL range. Immunological assays capable of quantifying LBP are preferably carried out by enzyme linked immunosorbant (ELISA) sandwich assays but competitive assays and immunological assays utilizing other labelling formats may also be used. Preferred assays of the invention utilize anti-LBP antibodies, including monoclonal antibodies and affinity-purified rabbit polyclonal antibodies. Rabbit polycelonal anti-LBP antibodies may be prepared according to conventional methods using LBP as an immunogen. Non-immunological methods may also be used to assay for LBP. As one example, Ulevitch et al., U.S. Pat. No. 5,245,013 disclose assay methods composing binding of LBP to LPS and separating the complex by a centrifugation density gradient method. As another example, Geller et al., Arch. Surg . 128: 22-28 (1993) disclose LBP bioactivity assays in which IL-6 and TNF upregulation are measured.
Body fluids which can be assayed for the presence of LBP include whole blood with blood serum and blood plasma being preferred. Because LBP is a serum protein it is contemplated that it could be excreted and that analysis of LBP levels in urine may provide diagnostic and prognostic utility. The LBP immunoassays of the invention may also be used to determine the concentration of LBP in other body fluids including, but not limited to lung elavages, vitreous fluid, crevicular fluid, cerebralspinal fluid, saliva and synovial fluid.
Because LBP has been characterized as an “acute phase protein” it would be expected that LBP levels would be elevated in subjects suffering from autoimmune diseases. As one aspect of the present invention it has been found that LBP levels are not generally elevated over normal in subjects suffering from acute lymphoblastic leukemia (ALL), acute graft versus host disease (aGvHD), chronic lymphocytic leukemia (CLL), cutaneous T-cell lymphoma (CTCL), type 1 diabetes, aplastic anemia (AA), Crohn's Disease, psoriasis, rheumatoid arthritis (RA), scleroderma, and systemic lupus erythematosus (SE).
Certain subjects tentatively identified as suffering from gram-negative sepsis but ultimately identified as suffering from gram-positive sepsis also had elevated LBP levels. It is noted that translocation of bacteria and/or endotoxin from the gut into the bloodstream can occur in any infection. Thus, infections due to gram-positive bacteria or fungi may also lead to the presence of endotoxin or gram-negative bacteria in the blood and, therefore elevated levels of LBP.
The present invention is based in part upon the observation that serum and plasma levels of LBP directly correlate with a subject's exposure to biologically active LPS. Moreover, LBP levels appear to correlate with survival in suspected gram-negative sepsis patients. For example, subjects with levels of circulating LBP below 27.3 μg/mL (the median value for 58 subjects suffering from gram-negative sepsis) tended to have a greater 14 day survival than did those subjects with levels of LBP above that median. Further, for example, when a plasma LBP threshold level was set at 46 μg/mL, those subjects having a pretreatment LBP plasma level less than 46 μg/mL had a significantly greater survival rate (p=0.004) over a 27 day period than did those subjects having a pretreatment plasma LBP level greater than 46 μg/mL.
It is further contemplated by the invention that elevated levels of LBP may result from exposure to larger amounts of endotoxin, and may therefore be diagnostic of greater infection and/or endotoxemia severity. Elevated levels of LBP may also be used to indicate the suitability of using antibiotics directed against gram-negative bacteria or other therapeutic agents targeted directly to endotoxin such as BPI or antie-ndotoxin antibodies including the monoclonal antibody E5.
Other aspects and advantages of the present invention will be understood upon consideration of the following illustrative examples. Example 1 relates to the preparation of affinity purified rabbit anti-BPI antibodies; Example 2 relates to the biotin labeling of such antibodies; and Example 3 relates to ELISA procedures utilizing such antibodies. Example 4 relates to the comparative immunoreactivity of rLBP, rLBP 25 , rBPI AND rBPI 23 . Example 5 relates to the measurement of rLBP spiked into pooled human plasma; and Example 6 relates to the comparison of LBP levels in human plasma and serum. Example 7 relates to the clinical correlations of endogenous LBP immunoreactivity with sepsis and other disease states in human plasma; and Example 8 relates to the effect of LPS administration on endogenous LBP levels in healthy subjects. Example 9 relates to clinical correlations between plasma LBP levels and survival in suspected gram-negative sepsis patients; and Example 10 relates to clinical correlations of acute phase proteins in healthy, rheumatoid arthritic and septic patients.
EXAMPLE 1
Preparation of Affinity Purified Rabbit Anti-rLBP Antibody
According to this example affinity purified rabbit anti-rLBP antibody was prepared. Specifically, rLBP (20 mg) produced according to co-owned and copending U.S. patent application Ser. No. 08/079,510 filed Jun. 17, 1993, the disclosure of which is hereby incorporated by reference was coupled to 10 mL of cyanogen bromide-activated Sepharose 4B (Sigma Chemical Co., St Louis, Mo.) in 0.2 M bicarbonate, pH 8.6, containing 0.5 NaCl. Approximately 94% of the rLBP was coupled to the resin. Pooled antisera (125 mL) from two rabbits, immunized initially with rLBP 25 produced according to the methods of U.S. patent application Ser. No. 08/079,510 filed Jun. 17, 1993 and thereafter with rLBP, were diluted with an equal volume of phosphate buffered saline, pH 7.2 (PBS). A portion (50 mL) of the diluted antisera was passed through the 10 mL rLBP-Sepharose column; the column was then washed with PBS and bound antibodies were eluted with 0.1 M glycine, pH 2.5. Collected fractions were immediately neutralized with 1 M phosphate buffer, pH 8.0. Peak fractions were identified by measuring absorbance at 280 nm according to the method of Harlow et al., Antibodies: A Laboratory Manual, Cold Springs Harbor Laboratory Press, New York, p. 312 (1988). After several sequential column cycles, the affinity purified rabbit anti-LBP antibody was dialyzed against PBS-azide pH 7.2.
EXAMPLE 2
Preparation of Biotin Labeled Rabbit Anti-rLBP Antibody
In this example twenty milligrams of affinity purified rabbit anti-rLBP antibody produced according to the method of Example 1 was incubated with 2 mg of biotinamidocaproate N-hydroxysuccinimide ester (Sigma Chemical Co., St. Louis, Mo.) in 11 mL of 0.1 M sodium bicarbonate pH 8.3 for two hours at room temperature. Unconjugated biotin was removed and the alkaline buffer exchanged by fractionating the reaction mixture on a PD-10 column (Pharmacia Biotech Inc., Piscataway, N.J.) equilibrated with PBS containing 0.1% sodium azide.
EXAMPLE 3
ELISA Procedure
Fifty microliters of affinity purified rabbit anti-rLBP antibody (2 μg/mL in PBS) were incubated overnight at 2-8° C. (or alternatively, 1 hour at 37° C.) in the wells of Immulon 2 (Dynatech Laboratories Inc., Chantilly, Va.) microtiter plates. The antibody solution was removed and 200 μL of 1% non-fat milk in PBS (blocking agent) was added to all wells. After blocking the plates for 1 hour at room temperature, the wells were washed 3 times with 300 μL of wash buffer (PBS/0.05% Tween-20).
Standards, samples and controls were diluted in triplicate with PBS containing 1% bovine serum albumin, 0.05% Tween 20 (PBS-BSA/Tween) and 10 units/mL of sodium heparin (Sigma Chemical Co., St. Louis, Mo.) in separate 96-well plates. rLBP or rLBP 25 standard solutions were prepared as serial two-fold dilutions from 100 to 0.012 ng/mL. Each replicate and dilution of the standards, samples and controls (50 μL) was transferred to the blocked microtiter plates and incubated for 1 hour at 37° C. After the primary incubation, the wells were washed 3 times with wash buffer. Biotin-labeled rabbit anti-LBP antibody was diluted 1/2000 in PBS-BSA/Tween and 50 μL was added to all wells. The plates were then incubated for 1 hour at 37° C. Subsequently, all wells were washed 3 times with wash buffer. Alkaline phosphatase-labeled streptavidin (Zymed Laboratories Inc., San Francisco, Calif.) was diluted 1/2000 in PBS-BSA/Tween and 50 μL was added to all wells. After incubation for 15 minutes at 37° C., all wells were washed 3times with wash buffer and 3 times with deionized water and the chromogenic substrate p-nitrophenylphosphate (1 mg/mL in 10% diethanolamine buffer) was added in a volume of 50 μL to all wells. Color development was allowed to proceed for 1 hour at room temperature, after which 50 μL of 1 N NaOH was added to stop the reaction. The absorbance at 405 nm was determined for all wells using a Vmax Plate Reader (Molecular Devices Corp., Menlo Park, Calif.).
The mean absorbance at 405 nm (A 405 ) for all samples and standards (in triplicate) were corrected for background by subtracting the mean A 405 of wells receiving only sample dilution buffer (no LBP) in the primary incubation step. A standard curve was then plotted as A 405 versus ng/mL of rLBP or rLBP 25 . The linear range was selected, a linear regression analysis was performed and concentrations were determined for samples and controls by interpolation from the standard curve.
EXAMPLE 4
Comparative Immunoreactivity of rLBP, rLBP 25 , rBPI AND rBPI 23
In this example, the immunoreactivity of rLBP, rLBP 25 , rBPI and BPI 23 were compared in the BPI sandwich ELISA to determine possible immunologic cross-reactivity. Despite considerable sequence homology between LBP and BPI (see, e.g., Schumann et al., Science , 249:1429 (1990), the results illustrated in FIG. 1 show that, on a mass basis, rBPI 23 produced a signal which was approximately 3 orders of magnitude lower than that of rLBP 25 and rLBP, while rBPI produced a signal that was approximately 5 orders of magnitude lower than that of rLBP and rLBP 25 . For example, a concentration of 100,000 ng/mL (100 μg/mL) of rBPI or 400 ng/mL rBPI 23 generated a signal which was equal to that produced by 0.8 ng/mL of rLBP or 0.4 ng/mL of rLBP 25 . These results demonstrate minimal cross-reactivity of the antibody with BPI and confirm the specificity of the assay for LBP.
EXAMPLE 5
Measurement of rLBP spiked into Pooled Human Plasma
In this example, the recovery of rLBP in human blood fluids was evaluated by examining pooled human plasma spiked with different concentrations of rLBP and then frozen and thawed prior to measurement in the sandwich ELISA. Recovery of spiked LBP was defined as the amount of LBP measured in spiked human plasma samples minus the concentration in the unspiked control, divided by the actual amount spiked in the sample. The fraction recovered was multiplied by 100 and the results were expressed as a percentage of the input concentration. Recovery of different concentrations of rLBP spiked into pooled human plasma samples averaged 68% and ranged from 59% at 42 μg/mL to 78% at 168 μg/mL. Table I summarizes the recovery data for each LBP spiked plasma sample.
TABLE I
Recovery of rLBP Spiked into Pooled Citrated Human Plasma
Amount Spiked
Amount Measured
Amount Recovered
Percent
(μg/mL)
(μg/mL)
(μg/mL)
Recovery
0
2.47
—
—
10.5
9.85
7.38
70%
21
16.1
13.63
65%
42
27.3
24.83
59%
84
60.8
58.33
69%
168
133
130.53
78%
Mean Recovery
68%
EXAMPLE 6
Comparison of Plasma and Serum LBP Levels
According to this example concentrations of LBP in the serum and plasma of healthy subjects were assayed and compared utilizing the sandwich ELISA assay according to Example 3. Plasma concentrations of LBP were found to be essentially the same as serum concentrations for LBP when the plasma volume was corrected for dilution (dividing by a factor of 0.85) resulting from the addition of anticoagulant. Plasma concentrations in normal human subjects were found to be 3.1 μg/mL (S.D. 0.9 μg/mL) or 3.7 μg/mL (S.D. 1.1 μl/mL) corrected, compared with 3.7 μg/mL (S.D. 0.9 μg/mL) for serum.
EXAMPLE 7
Clinical Correlations of Endogenous LBP Immunoreactivity in Human Plasma
In this example endogenous LBP immunoreactivity was measured in human plasma or serum samples collected from a variety of subjects suffering from gram-negative sepsis and a variety of other clinical conditions. Specifically, plasma samples of healthy individuals (30 subjects) and individuals diagnosed with gram-negative sepsis (363 subjects) were assayed for LBP levels. Serum samples of individuals with acute lymphoblastic leukemia (ALL) (6 subjects); acute graft versus host disease (aGvHD) (8 subjects); chronic lymphocytic leukemia (CLL) (9 subjects); cutaneous T-cell lymphoma (CTCL) (12 subjects); type 1 diabetes (13 subjects); a plastic anemia (AA) (16 subjects); Crohn's Disease (8 subjects); psoriasis (13 subjects); rheumatoid arthritis (RA) (86 subjects); scleroderma (4 subjects), and systemic lupus erythematosus (SLE) (10 subjects) were assayed for LBP levels. The results are shown in FIG. 2 .
While LBP levels among subjects diagnosed as suffering from gram-negative sepsis were elevated it was found that LBP levels are not elevated over normal in subjects suffering from acute lymphoblastic leukemia, acute graft versus host disease, chronic lymphocytic leukemia, cutaneous T-cell lymphoma, type 1 diabetes, aplastic anemia, Crohn's Disease, psoriasis, rheumatoid arthritis, scleroderma, and systemic lupus erythematosus (SLE). Accordingly, the LBP assay of the invention is valuable for distinguishing conditions associated with endotoxin from other acute phase conditions (such as RA, SLE and the like).
EXAMPLE 8
The Effect of LPS Administration on Endogenous LBP Levels in Healthy Subjects
In this example, the effect of LPS administration on endogenous LBP immunoreactivity in healthy human subjects was determined. Specifically, healthy subjects were monitored utilizing the LBP sandwich assay for changes in LBP plasma levels at various time points after intravenous administration of 4 ng/kg LPS (16 subjects) or in control subjects (2) not receiving LPS. The results illustrated in FIG. 3 show the change in mean plasma LBP concentration with time. For those subjects treated with LPS LBP levels began to rise about 6 hours after LPS administration. Peak LBP plasma levels were observed in most subjects between 10 to 12 hours after the LPS administration. The average increase from baseline to peak LBP level was approximately 3-fold. Over this time period the mean LBP levels in control subjects remained within normal range (approximately 5 μg/mL).
It is contemplated that additional analysis will illustrate the correlation of LBP levels in body fluids with the symptoms of exposure to endotoxin and that LBP levels will be diagnostic and prognostic of disease states resulting from exposure to endotoxin.
It is contemplated that additional analysis will illustrate the correlation of LBP levels with symptoms of bacterial infections, endotoxemia and sepsis including conditions associated with sepsis including DIC and ARDS.
EXAMPLE 9
Clinical Correlations Between Plasma LBP Levels and Survival in suspected Gram-Negative Sepsis Patients
Correlations between plasma LBP levels and survival in suspected gram-negative sepsis patients were compared using data obtained from the septic subjects described in Example 7. In this case, a standard LBP concentration was set at 46 μg/mL and patients with suspected gram-negative sepsis were classified as having either high (>46 μg/mL) or low (<46 μg/mL) LBP plasma levels as measured in pretreatment samples. As shown in the data presented in FIG. 4, those subjects having low pretreatment plasma levels of LBP had a significantly greater survival rate (p=0.004) over a 27 day period than did those subjects having a high pretreatment plasma LBP level. These data show the utility of assaying LBP levels and comparing them to a standard LBP value for predicting the prognosis of subjects suffering from sepsis.
EXAMPLE 10
Clinical Correlations of Acute Phase Proteins in Healthy, Rheumatoid Arthritic, and Septic Patients
Plasma levels of LBP, C-reactive protein (CRP) and fibrinogen were measured in small groups of healthy, rheumatoid arthritic and septic patients with the results shown in FIGS. 5 a (LMP levels), 5 b (CRP levels) and 5 c (fibrinogen levels). The results show that relative to healthy subjects, mean fibrinogen levels were elevated approximately 2.5 fold for both rheumatoid arthritic and septic subjects. Relative to healthy subjects, mean CRP levels were found to be elevated approximately 40-fold for rheumatoid arthritic subjects and 200-fold for septic subjects. In contrast, and consistent with the results in Example 7, mean LBP levels were only slightly increased (less than 2-fold) for rheumatoid arthritis subjects while the mean LBP levels were increased by more than 6 fold for septic subjects.
Numerous modifications and variations in the practice of the invention are expected to occur to those skilled in the art upon consideration of the foregoing description of the presently preferred embodiments thereof. Consequently, the only limitations which should be placed upon the scope of the present invention are those which appear in the appended claims.
4
1443 base pairs
nucleic acid
single
linear
DNA
not provided
CDS
1..1443
mat_peptide
76..1443
misc_feature
“rLBP”
1
ATG GGG GCC TTG GCC AGA GCC CTG CCG TCC ATA CTG CTG GCA TTG CTG 48
Met Gly Ala Leu Ala Arg Ala Leu Pro Ser Ile Leu Leu Ala Leu Leu
-25 -20 -15 -10
CTT ACG TCC ACC CCA GAG GCT CTG GGT GCC AAC CCC GGC TTG GTC GCC 96
Leu Thr Ser Thr Pro Glu Ala Leu Gly Ala Asn Pro Gly Leu Val Ala
-5 1 5
AGG ATC ACC GAC AAG GGA CTG CAG TAT GCG GCC CAG GAG GGG CTA TTG 144
Arg Ile Thr Asp Lys Gly Leu Gln Tyr Ala Ala Gln Glu Gly Leu Leu
10 15 20
GCT CTG CAG AGT GAG CTG CTC AGG ATC ACG CTG CCT GAC TTC ACC GGG 192
Ala Leu Gln Ser Glu Leu Leu Arg Ile Thr Leu Pro Asp Phe Thr Gly
25 30 35
GAC TTG AGG ATC CCC CAC GTC GGC CGT GGG CGC TAT GAG TTC CAC AGC 240
Asp Leu Arg Ile Pro His Val Gly Arg Gly Arg Tyr Glu Phe His Ser
40 45 50 55
CTG AAC ATC CAC AGC TGT GAG CTG CTT CAC TCT GCG CTG AGG CCT GTC 288
Leu Asn Ile His Ser Cys Glu Leu Leu His Ser Ala Leu Arg Pro Val
60 65 70
CCT GGC CAG GGC CTG AGT CTC AGC ATC TCC GAC TCC TCC ATC CGG GTC 336
Pro Gly Gln Gly Leu Ser Leu Ser Ile Ser Asp Ser Ser Ile Arg Val
75 80 85
CAG GGC AGG TGG AAG GTG CGC AAG TCA TTC TTC AAA CTA CAG GGC TCC 384
Gln Gly Arg Trp Lys Val Arg Lys Ser Phe Phe Lys Leu Gln Gly Ser
90 95 100
TTT GAT GTC AGT GTC AAG GGC ATC AGC ATT TCG GTC AAC CTC CTG TTG 432
Phe Asp Val Ser Val Lys Gly Ile Ser Ile Ser Val Asn Leu Leu Leu
105 110 115
GGC AGC GAG TCC TCC GGG AGG CCC ACA GTT ACT GCC TCC AGC TGC AGC 480
Gly Ser Glu Ser Ser Gly Arg Pro Thr Val Thr Ala Ser Ser Cys Ser
120 125 130 135
AGT GAC ATC GCT GAC GTG GAG GTG GAC ATG TCG GGA GAC TTG GGG TGG 528
Ser Asp Ile Ala Asp Val Glu Val Asp Met Ser Gly Asp Leu Gly Trp
140 145 150
CTG TTG AAC CTC TTC CAC AAC CAG ATT GAG TCC AAG TTC CAG AAA GTA 576
Leu Leu Asn Leu Phe His Asn Gln Ile Glu Ser Lys Phe Gln Lys Val
155 160 165
CTG GAG AGC AGG ATT TGC GAA ATG ATC CAG AAA TCG GTG TCC TCC GAT 624
Leu Glu Ser Arg Ile Cys Glu Met Ile Gln Lys Ser Val Ser Ser Asp
170 175 180
CTA CAG CCT TAT CTC CAA ACT CTG CCA GTT ACA ACA GAG ATT GAC AGT 672
Leu Gln Pro Tyr Leu Gln Thr Leu Pro Val Thr Thr Glu Ile Asp Ser
185 190 195
TTC GCC GAC ATT GAT TAT AGC TTA GTG GAA GCC CCT CGG GCA ACA GCC 720
Phe Ala Asp Ile Asp Tyr Ser Leu Val Glu Ala Pro Arg Ala Thr Ala
200 205 210 215
CAG ATG CTG GAG GTG ATG TTT AAG GGT GAA ATC TTT CAT CGT AAC CAC 768
Gln Met Leu Glu Val Met Phe Lys Gly Glu Ile Phe His Arg Asn His
220 225 230
CGT TCT CCA GTT ACC CTC CTT GCT GCA GTC ATG AGC CTT CCT GAG GAA 816
Arg Ser Pro Val Thr Leu Leu Ala Ala Val Met Ser Leu Pro Glu Glu
235 240 245
CAC AAC AAA ATG GTC TAC TTT GCC ATC TCG GAT TAT GTC TTC AAC ACG 864
His Asn Lys Met Val Tyr Phe Ala Ile Ser Asp Tyr Val Phe Asn Thr
250 255 260
GCC AGC CTG GTT TAT CAT GAG GAA GGA TAT CTG AAC TTC TCC ATC ACA 912
Ala Ser Leu Val Tyr His Glu Glu Gly Tyr Leu Asn Phe Ser Ile Thr
265 270 275
GAT GAG ATG ATA CCG CCT GAC TCT AAT ATC CGA CTG ACC ACC AAG TCC 960
Asp Glu Met Ile Pro Pro Asp Ser Asn Ile Arg Leu Thr Thr Lys Ser
280 285 290 295
TTC CGA CCC TTC GTC CCA CGG TTA GCC AGG CTC TAC CCC AAC ATG AAC 1008
Phe Arg Pro Phe Val Pro Arg Leu Ala Arg Leu Tyr Pro Asn Met Asn
300 305 310
CTG GAA CTC CAG GGA TCA GTG CCC TCT GCT CCG CTC CTG AAC TTC AGC 1056
Leu Glu Leu Gln Gly Ser Val Pro Ser Ala Pro Leu Leu Asn Phe Ser
315 320 325
CCT GGG AAT CTG TCT GTG GAC CCC TAT ATG GAG ATA GAT GCC TTT GTG 1104
Pro Gly Asn Leu Ser Val Asp Pro Tyr Met Glu Ile Asp Ala Phe Val
330 335 340
CTC CTG CCC AGC TCC AGC AAG GAG CCT GTC TTC CGG CTC AGT GTG GCC 1152
Leu Leu Pro Ser Ser Ser Lys Glu Pro Val Phe Arg Leu Ser Val Ala
345 350 355
ACT AAT GTG TCC GCC ACC TTG ACC TTC AAT ACC AGC AAG ATC ACT GGG 1200
Thr Asn Val Ser Ala Thr Leu Thr Phe Asn Thr Ser Lys Ile Thr Gly
360 365 370 375
TTC CTG AAG CCA GGA AAG GTA AAA GTG GAA CTG AAA GAA TCC AAA GTT 1248
Phe Leu Lys Pro Gly Lys Val Lys Val Glu Leu Lys Glu Ser Lys Val
380 385 390
GGA CTA TTC AAT GCA GAG CTG TTG GAA GCG CTC CTC AAC TAT TAC ATC 1296
Gly Leu Phe Asn Ala Glu Leu Leu Glu Ala Leu Leu Asn Tyr Tyr Ile
395 400 405
CTT AAC ACC TTC TAC CCC AAG TTC AAT GAT AAG TTG GCC GAA GGC TTC 1344
Leu Asn Thr Phe Tyr Pro Lys Phe Asn Asp Lys Leu Ala Glu Gly Phe
410 415 420
CCC CTT CCT CTG CTG AAG CGT GTT CAG CTC TAC GAC CTT GGG CTG CAG 1392
Pro Leu Pro Leu Leu Lys Arg Val Gln Leu Tyr Asp Leu Gly Leu Gln
425 430 435
ATC CAT AAG GAC TTC CTG TTC TTG GGT GCC AAT GTC CAA TAC ATG AGA 1440
Ile His Lys Asp Phe Leu Phe Leu Gly Ala Asn Val Gln Tyr Met Arg
440 445 450 455
GTT 1443
Val
481 amino acids
amino acid
linear
protein
not provided
misc_feature
“rLBP”
2
Met Gly Ala Leu Ala Arg Ala Leu Pro Ser Ile Leu Leu Ala Leu Leu
-25 -20 -15 -10
Leu Thr Ser Thr Pro Glu Ala Leu Gly Ala Asn Pro Gly Leu Val Ala
-5 1 5
Arg Ile Thr Asp Lys Gly Leu Gln Tyr Ala Ala Gln Glu Gly Leu Leu
10 15 20
Ala Leu Gln Ser Glu Leu Leu Arg Ile Thr Leu Pro Asp Phe Thr Gly
25 30 35
Asp Leu Arg Ile Pro His Val Gly Arg Gly Arg Tyr Glu Phe His Ser
40 45 50 55
Leu Asn Ile His Ser Cys Glu Leu Leu His Ser Ala Leu Arg Pro Val
60 65 70
Pro Gly Gln Gly Leu Ser Leu Ser Ile Ser Asp Ser Ser Ile Arg Val
75 80 85
Gln Gly Arg Trp Lys Val Arg Lys Ser Phe Phe Lys Leu Gln Gly Ser
90 95 100
Phe Asp Val Ser Val Lys Gly Ile Ser Ile Ser Val Asn Leu Leu Leu
105 110 115
Gly Ser Glu Ser Ser Gly Arg Pro Thr Val Thr Ala Ser Ser Cys Ser
120 125 130 135
Ser Asp Ile Ala Asp Val Glu Val Asp Met Ser Gly Asp Leu Gly Trp
140 145 150
Leu Leu Asn Leu Phe His Asn Gln Ile Glu Ser Lys Phe Gln Lys Val
155 160 165
Leu Glu Ser Arg Ile Cys Glu Met Ile Gln Lys Ser Val Ser Ser Asp
170 175 180
Leu Gln Pro Tyr Leu Gln Thr Leu Pro Val Thr Thr Glu Ile Asp Ser
185 190 195
Phe Ala Asp Ile Asp Tyr Ser Leu Val Glu Ala Pro Arg Ala Thr Ala
200 205 210 215
Gln Met Leu Glu Val Met Phe Lys Gly Glu Ile Phe His Arg Asn His
220 225 230
Arg Ser Pro Val Thr Leu Leu Ala Ala Val Met Ser Leu Pro Glu Glu
235 240 245
His Asn Lys Met Val Tyr Phe Ala Ile Ser Asp Tyr Val Phe Asn Thr
250 255 260
Ala Ser Leu Val Tyr His Glu Glu Gly Tyr Leu Asn Phe Ser Ile Thr
265 270 275
Asp Glu Met Ile Pro Pro Asp Ser Asn Ile Arg Leu Thr Thr Lys Ser
280 285 290 295
Phe Arg Pro Phe Val Pro Arg Leu Ala Arg Leu Tyr Pro Asn Met Asn
300 305 310
Leu Glu Leu Gln Gly Ser Val Pro Ser Ala Pro Leu Leu Asn Phe Ser
315 320 325
Pro Gly Asn Leu Ser Val Asp Pro Tyr Met Glu Ile Asp Ala Phe Val
330 335 340
Leu Leu Pro Ser Ser Ser Lys Glu Pro Val Phe Arg Leu Ser Val Ala
345 350 355
Thr Asn Val Ser Ala Thr Leu Thr Phe Asn Thr Ser Lys Ile Thr Gly
360 365 370 375
Phe Leu Lys Pro Gly Lys Val Lys Val Glu Leu Lys Glu Ser Lys Val
380 385 390
Gly Leu Phe Asn Ala Glu Leu Leu Glu Ala Leu Leu Asn Tyr Tyr Ile
395 400 405
Leu Asn Thr Phe Tyr Pro Lys Phe Asn Asp Lys Leu Ala Glu Gly Phe
410 415 420
Pro Leu Pro Leu Leu Lys Arg Val Gln Leu Tyr Asp Leu Gly Leu Gln
425 430 435
Ile His Lys Asp Phe Leu Phe Leu Gly Ala Asn Val Gln Tyr Met Arg
440 445 450 455
Val
591 base pairs
nucleic acid
single
linear
DNA
not provided
CDS
1..591
misc_feature
“rLBP25”
3
GCC AAC CCC GGC TTG GTC GCC AGG ATC ACC GAC AAG GGA CTG CAG TAT 48
Ala Asn Pro Gly Leu Val Ala Arg Ile Thr Asp Lys Gly Leu Gln Tyr
1 5 10 15
GCG GCC CAG GAG GGG CTA TTG GCT CTG CAG AGT GAG CTG CTC AGG ATC 96
Ala Ala Gln Glu Gly Leu Leu Ala Leu Gln Ser Glu Leu Leu Arg Ile
20 25 30
ACG CTG CCT GAC TTC ACC GGG GAC TTG AGG ATC CCC CAC GTC GGC CGT 144
Thr Leu Pro Asp Phe Thr Gly Asp Leu Arg Ile Pro His Val Gly Arg
35 40 45
GGG CGC TAT GAG TTC CAC AGC CTG AAC ATC CAC AGC TGT GAG CTG CTT 192
Gly Arg Tyr Glu Phe His Ser Leu Asn Ile His Ser Cys Glu Leu Leu
50 55 60
CAC TCT GCG CTG AGG CCT GTC CCT GGC CAG GGC CTG AGT CTC AGC ATC 240
His Ser Ala Leu Arg Pro Val Pro Gly Gln Gly Leu Ser Leu Ser Ile
65 70 75 80
TCC GAC TCC TCC ATC CGG GTC CAG GGC AGG TGG AAG GTG CGC AAG TCA 288
Ser Asp Ser Ser Ile Arg Val Gln Gly Arg Trp Lys Val Arg Lys Ser
85 90 95
TTC TTC AAA CTA CAG GGC TCC TTT GAT GTC AGT GTC AAG GGC ATC AGC 336
Phe Phe Lys Leu Gln Gly Ser Phe Asp Val Ser Val Lys Gly Ile Ser
100 105 110
ATT TCG GTC AAC CTC CTG TTG GGC AGC GAG TCC TCC GGG AGG CCC ACA 384
Ile Ser Val Asn Leu Leu Leu Gly Ser Glu Ser Ser Gly Arg Pro Thr
115 120 125
GTT ACT GCC TCC AGC TGC AGC AGT GAC ATC GCT GAC GTG GAG GTG GAC 432
Val Thr Ala Ser Ser Cys Ser Ser Asp Ile Ala Asp Val Glu Val Asp
130 135 140
ATG TCG GGA GAC TTG GGG TGG CTG TTG AAC CTC TTC CAC AAC CAG ATT 480
Met Ser Gly Asp Leu Gly Trp Leu Leu Asn Leu Phe His Asn Gln Ile
145 150 155 160
GAG TCC AAG TTC CAG AAA GTA CTG GAG AGC AGG ATT TGC GAA ATG ATC 528
Glu Ser Lys Phe Gln Lys Val Leu Glu Ser Arg Ile Cys Glu Met Ile
165 170 175
CAG AAA TCG GTG TCC TCC GAT CTA CAG CCT TAT CTC CAA ACT CTG CCA 576
Gln Lys Ser Val Ser Ser Asp Leu Gln Pro Tyr Leu Gln Thr Leu Pro
180 185 190
GTT ACA ACA GAG ATT 591
Val Thr Thr Glu Ile
195
197 amino acids
amino acid
linear
protein
not provided
misc_feature
“rLBP25”
4
Ala Asn Pro Gly Leu Val Ala Arg Ile Thr Asp Lys Gly Leu Gln Tyr
1 5 10 15
Ala Ala Gln Glu Gly Leu Leu Ala Leu Gln Ser Glu Leu Leu Arg Ile
20 25 30
Thr Leu Pro Asp Phe Thr Gly Asp Leu Arg Ile Pro His Val Gly Arg
35 40 45
Gly Arg Tyr Glu Phe His Ser Leu Asn Ile His Ser Cys Glu Leu Leu
50 55 60
His Ser Ala Leu Arg Pro Val Pro Gly Gln Gly Leu Ser Leu Ser Ile
65 70 75 80
Ser Asp Ser Ser Ile Arg Val Gln Gly Arg Trp Lys Val Arg Lys Ser
85 90 95
Phe Phe Lys Leu Gln Gly Ser Phe Asp Val Ser Val Lys Gly Ile Ser
100 105 110
Ile Ser Val Asn Leu Leu Leu Gly Ser Glu Ser Ser Gly Arg Pro Thr
115 120 125
Val Thr Ala Ser Ser Cys Ser Ser Asp Ile Ala Asp Val Glu Val Asp
130 135 140
Met Ser Gly Asp Leu Gly Trp Leu Leu Asn Leu Phe His Asn Gln Ile
145 150 155 160
Glu Ser Lys Phe Gln Lys Val Leu Glu Ser Arg Ile Cys Glu Met Ile
165 170 175
Gln Lys Ser Val Ser Ser Asp Leu Gln Pro Tyr Leu Gln Thr Leu Pro
180 185 190
Val Thr Thr Glu Ile
195
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The present invention provides a method for quantifying the presence of extracellular LBP in body fluids including blood in a subject comprising conducting an LBP immunoassay on plasma obtained from said subject.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to control of surgical drainage and seroma prevention in surgical and trauma wounds and, in particular, to applying talc in the wounds to induce a localized inflammatory reaction to reduce the fluids that may accumulate.
DESCRIPTION OF THE RELATED ART
[0002] It will be appreciated by those skilled in the art that talc, doxycycline, tetracycline, erythromycin, bleomycin, and polidocanol can be used to treat retained fluid and effusions in the chest cavity and pleural space. With the fluid drained by various methods, the administration of all of these agents results in a controlled, local inflammatory response that seals the lung to the chest wall and prevents fluid re-accumulation.
[0003] Surgical procedures that require a significant soft tissue dissection and/or lymph node resection result in loss of fluid from the cut surface of those tissues or weeping of lymphatic fluid. The collection of this tissue or lymphatic fluids under a patient's skin or within the surgical wound, otherwise known as a seroma, can lead to wound breakdown, infection, discomfort, scarring, or other chronic wound issues and the need for repeated drainage procedures or surgical operations. Currently, near the completion of an operation, surgeons place drainage tubes in the operative tissues to collect this fluid in an attempt to prevent a seroma from occurring. Over the past three decades better wound preparation, and improved tissue coagulation instruments and surgical techniques have done little to reduce seroma development and its subsequent complications.
[0004] Pleural effusions differ significantly from seromas both by location, pathophysiology, and indications for treatment. The pleural space is a closed serous sac. The pleura consists of two parts, the parietal pleura, which is applied to the thoracic wall, and the visceral pleura, which covers the surface lung. Each of these pleural surfaces is lined by a mesothelial layer that constantly secretes fluid. This fluid acts as a lubricant that allows the lung to slide or move along the inner chest cavity during the process of breathing. Finding fluid in this space is normal, and, in fact, it is estimated that more than 5000 ml of fluid transgresses this space every day in adults. Pleural effusions, an abnormal collection of fluid in the pleural space, typically results from cancer, either primary or metastatic. The fluid that normally exists in the pleural space is not collected by the pleura, has a dramatic increase in protein content due to increased capillary permeability, and impacts the patient's ability to breath by compressing the lung.
[0005] Seroma fluid originates primarily from weeping fluid due to direct tissue trauma inflicted at the time of operation and from surgically disrupted lymphatic channels. The seroma fluid collects in the area of the operative field and is not typically found “free” in these areas. Unlike the chest cavity, the space where the seroma fluid collects does not exist until an operation opens it. Seromas are not directly caused by cancer, but may be secondary to the surgical treatment of cancer.
[0006] The wounds from surgery and trauma provide the tissue injury that results in the accumulation of wound fluid and seroma formation. It is also well know by those skilled in the art that seromas lead to surgical wound complications in operations such as hernia repairs, breast cancer procedures, lymph node resections, hip replacements, free tissue flaps, panniculectomies, tummy tucks, soft tissue and muscles flaps and transfers, and others. If these fluid collections are not controlled, high levels of morbidity can result. Often, surgeons place drainage tubes in the patients' wounds to remove the fluid. However, the drain tubes frequently fail, become infected themselves, or are required to be in place for weeks post-operatively resulting in discomfort, scarring, and other problems along with a reduction in patient quality of life.
[0007] Seroma formation following complex procedures such as ventral hernia repair, orthopedic, plastic surgery and cancer operations are serious, painful, expensive to treat, and can lead to additional serious complications. The very minor to major infection rates following these procedures can exceed 30 percent. An additional problem of postoperative care is a huge cost to the health care system, the treatment of which can exceed the cost of the original surgery.
[0008] What is needed then is a method of lowering the incidence of seromas following surgery by providing an effective agent at the site of the wound at the time of the surgery or trauma that is non-toxic and results in rapid tissue attachment which eliminates tissue/lymphatic weeping in the space in which the seroma forms. The method of reduction in the rate of seroma formation will most likely allow earlier removal of drains, therefore, reduce the complications associated with the drains themselves and improve patient quality of life.
Quantitative Complication Reduction
[0009] Those skilled in the art are aware that sterile talc, doxycycline, tetracycline, bleomycin, erythromycin and polidocanol are effective agents to treat pleural effusions but do not respond to simple drainage. Talc has been utilized for many years. Talc as a pure chemical compound is defined as hydrous magnesium silicate, Mg 3 Si 4 O 10 (OH) 2 . A variety of elements such as nickel and iron may be included in the talc particle lattice, but are so bound within the particle that they are not free to exert any biological action. (Gross and Harley, 1973). Talc can be tabular, granular, fibrous, or platy, but it is usually crystalline, flexible, and soft. As described by Colt and many others, talc is effective in 80%-90% of cases with a safe adverse-event profile. (Colt—The Lancet—Oncology; Vol 9, Page 912; October, 2009). Of the more than 30 randomized, prospective trials, most favor talc to treat recurrent pleural fluid collections. Indeed, the Cochrane review ranks it as the pleurodesis agent of choice [Shaw P, Agarwal R. Pleurodesis for malignant pleural effusions (Cochrane Review). Cochrane Database Syst Rev 2004; CD002916.]. It can be effective when administered by either poudrage or slurry. It can be used as large particle, small particle, or a combination of both. Small particle talc has been associated with greater rate of complications when used in the pleural space of the chest and is related to adult respiratory syndrome due to the direct absorption.
[0010] Erythromycin is primarily used as an oral antibiotic to treat gram-positive bacteria. It has been utilized as a pleural sclerosing agent. When placed in the pleural space it can result in adherence of the lung to the chest wall. The use of erythromycin may have the advantage of a reduction in inflammation as described by Miller (J of Surg Education; Vol 64, No.1, January 2007), but the extent of fibrosis remains high, which results in the fibrosis and the desired effect of collapse of the pleural space. Its first use in recurrent pleural fluid collections was in 1935. Its use is uncommon in clinical practice and there is limited human data. Doxycycline and tetracycline are primarily used as antibiotics taken orally. The application of these agents for retained or recurrent pleural fluid collections has been described as safe for many years. There are several descriptions of their success. Patz (Chest, 1998) demonstrated a 79% success rate in completely or partially controlling pleural effusions with doxyclycline. In a head-to-head study published in the Medical Science Monitor in 2004 (Kuzdal, et.al. Management of Recurrent Malignant Pleural Effusions with Chemical Pleurodesis), doxycycline did not perform as well as talc, which had significantly higher rates of response both short and long term. Miller described in an animal model that Doxycycline may cause more inflammation than other agents. (J of Surg Education; Vol 64, No. 1, January 2007).
[0011] Bleomycin, a chemotherapy medication, appears to have few side effects, but is somewhat less effective and more expensive when compared to talc for pluerodesis. This was documented in a retrospective review by Kilic (Surgery Today 2004) when their group that used talc allowed for earlier drain removal, fastest lung re-expansion, and greater overall success than bleomycin. Patz (Chest, 1998) demonstrated a 72% success rate in completely or partially controlling pleural effusions with bleomycin.
[0012] Polidocanol has typically been used as a sclerosing agent for extremity or esophageal varices. It is relatively less well studied for pluerodesis than the other agents. Cetin (Surgery Today 2003) did report that it compared well to tetracycline in animal models in the control of pleural fluid accumulation. No prospective studies in humans are available.
[0013] Combination of talc with other agents, such as doxycycline, has demonstrated good results in animal studies. Dikensoy's study of these combined showed statistically higher adhesion scores than either of these agents alone. (Chest, 2005). The possibility of a combination of other agents with talc, such as thrombin (a hemostatic agent), also exist.
[0014] The formation of seromas in post-surgical wounds such as hernia repair, lymph node resection, tummy tuck, panniculectomy, free or attached flaps, tissue transfers, and other major operations with a large dissection is ubiquitous unless drains are placed at the time of surgery. Despite drain placement, seromas still form, and the subsequent complication rates and reduction in patient quality of life can be high. Wound infection/cellulitis can exceed 30%, and office, operative or radiographic intervention can be required in 20% of patients.
[0015] The pathophysiology and location of pleural effusions and seromas are dramatically different. As well, pleurodesis as a preemptive treatment for an anticipated pleural effusion does not occur. In this patent, materials and methods for preemptive therapy for the prevention of seromas is described. These materials and methods are shown to be very effective in the treatment of this troublesome problem.
[0016] An anti-seroma agent would ideally be placed into the wound in question at the time of the original surgery. The goal would be to induce a very localized inflammatory reaction that would cause the weeping, cut surfaces of the wound to stick to surrounding tissues, thereby sealing them and the lymphatic vessels, while at the same time eliminating the space in which the fluid accumulates. By doing so, the wounds can heal and the surgical drains can be removed much earlier than previously, subsequently decreasing wound and drain-related complications.
SUMMARY OF THE INVENTION
[0017] The present invention is directed to a method for controlling seromas in non-pleural spaces in a mammal that includes performing a surgical procedure in a non-pleural space, the surgical procedure creating at least one subcutaneous tissue surface, applying talc to the at least one subcutaneous tissue surface to induce an inflammatory response on the at least one subcutaneous tissue surface, placing a drain in the non-pleural space, and closing the non-pleural space.
[0018] Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows and the claims.
[0019] It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] We performed a study evaluating a novel intra-operative technique of applying talc to the subcutaneous flaps created during panniculetomies, tummy tucks and hernia repair to prevent seroma formation. Following the operative dissection and otherwise completion of the operation except for wound closure, talc is sprayed into the wound in volumes from 4 grams to 8 grams. A large particle or mixed large and small particle talc were sprayed on all surfaces of the wound. This was performed with and without applying the hemostatic agent thrombin.
[0021] The data were collected prospectively identifying all patients undergoing these operations. Patients were divided into two groups based on receiving talc therapy. The PRE group did not receive talc therapy, and the POST group did receive talc therapy in the subcutaneous dissection. Patient demographics, peri-operative data, and outcomes were analyzed using standard statistical methods. The PRE group consisted of 108 patients and the POST group consisted of 61 patients. Patient demographic and peri-operative data, including patient age, race proportions, comorbidities, the type and extent of subcutaneous procedures, size of hernias, operative time, and others factors were similar between groups. Complication rates for PRE/ POST were: cellulites/oral antibiotics 39%/15%, intravenous antibiotics 10%/3%, operative/radiologic intervention for wound infection 22%/13%, seroma intervention 20%/4%, wound breakdown 11%/2%, and hernia recurrence 10%/0%. Of these, the incidence of cellulitis, antibiotic use, seroma intervention, wound complications, and hernia recurrence were significantly decreased in the POST group (p<0.05 in all groups). Mean drain duration was 28.4 days for PRE and 15.3 days for POST (p=0.0009).
[0022] The addition of talc or talc and thrombin made a dramatic difference in patient outcomes. It reduced the risk of infection, the need for antibiotics, significant wound issues, and the need for instrumentation or operation on seromas. As well, the patients' drains were removed remarkably early after the procedure. The wounds were closed with 4 grams of talc early in the study. Eight grams of talc were used later. The data from these time periods indicates that there may be a dose dependant outcome. The last 10 patients received 8 grams in their wounds and each had their drains removed by 12 days after the surgery. The addition of thrombin may be additive, given its hemostatic properties, but its exact contribution is not known.
Example
Wound Treatment
[0023] Surgical treatment of very large ventral hernias with concomitant panniculectomies or massive subcutaneous dissections were performed.
[0024] The typical operation included a wide skin and subcutaneous incision with significant subcutaneous dissection with and without skin resection. The ventral abdomen was entered, and the intestinal contents of the hernia were reduced back into the abdomen. The hernia was repaired with mesh, either placed under the muscular abdominal wall or on top of it. The subcutaneous tissues were irrigated and either closed or talc was sprayed or instilled in the wound with or without a coagulant (thrombin) prior to closure.
[0025] Closure of the abdomen was performed in the same manner in all patients regarding the sutures used and drains placed. Two flat Jackson-Pratt type drains were placed through the skin and into the subcutaneous space. They were left in place until less than 30 cc of fluid was drained over 24 hours. When either or both of the drains collected less than 30 cc of fluid, the drains were removed.
[0026] There were 169 patients were that divided into two groups based on whether or not they received talc therapy.
[0027] Following the prospective collection of data (patient demographics, peri-operative findings, and outcomes), the data were statistically analyzed.
Patient Outcomes
[0028] The group that did not receive talc included 108 patients while the talc group included 61 patients. Patient demographic and peri-operative data, including patient age, race proportions, comorbidities, the type and extent of subcutaneous procedures, size of hernias, operative time, and others factors were similar between groups.
[0029] Complication rates for No Talc/Talc groups were: cellulites requiring oral antibiotics: 39%/15%; intravenous antibiotics: 10%/3%; operative/radiologic intervention for wound infection: 22%/13%; seroma intervention: 20%/4%; wound breakdown: 11%/2%; and hernia recurrence: 10%/0%. Of these, incidence of cellulitis, antibiotic use, seroma intervention, wound complications, and hernia recurrence were significantly decreased in the group of patients receiving talc (p<0.05 in all groups).
[0030] The subcutaneous drains that were placed at the time of surgery were removed much sooner in the patients that had received talc therapy. Mean drain duration was 28.4 days for patients that did not receive talc. It was 15.3 days for patients receiving talc in their subcutaneous space prior to wound closure (p=0.0009).
Method of Use—Additional Sclerosing Agents
[0031] Following dissection and required operative procedures for paniculectomy, tummy tuck, ventral hernia repair, free or attached flap procedures, or other procedures that require broad dissection in the subcutaneous plane or other body areas, bleomycin, erythromycin, tetracycline, doxycycline, polidocanol alone or in combination or combined with talc and/or thrombin, is to be placed in the wound via spray, directly, or as a slurry. The standard drain placement and closure follow. The incidence of seroma formation and the need for prolonged drains in the wound should be minimized.
Method of Use—Talc Used in Lymph Node Resection
[0032] Following standard resection of axillary, groin, peri-iliac, neck lymph nodes, or other lymph node barring areas, 2-4 grams of talc, with or without thrombin, is to be placed in the wound via spray, directly, or as a slurry. The standard drain placement and closure follow. The incidence of seroma formation and the need for prolonged drains in the wound was minimized.
Method of Use—Additional Sclerosing Agents Used in Lymph Node Resection
[0033] Following standard resection of axillary, groin, peri-iliac, neck lymph nodes, or other lymph node barring areas, bleomycin, erythromycin, tetracycline, doxycycline, polidocanol alone or in combination or combined with talc and/or thrombin, is to be placed in the wound via spray, directly, or as a slurry. The standard drain placement and closure follow. The incidence of seroma formation and the need for prolonged drains in the wound was minimized.
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Apparatus and methods for significant reduction of seroma formation, seroma related complications and time until drain removal following surgery are disclosed. Talc, with and without thrombin, bleomycin, erythromycin, tetracycline, doxycycline, polidocanol alone or in combination or combined with talc and/or thrombin for use in operatives wound and lymph node dissections to reduce seromas are disclosed.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to hydrocarbon reformation and, more particularly, to the reformation of a hydrocarbon stream in the production of hydrogenous fuels.
BRIEF SUMMARY OF THE INVENTION
[0002] Carbonaceous material is removed from a catalyst within an autothermal reformer and catalyst heating mechanisms are improved by introducing an isolated oxidant stream into the autothermal reformer prior to introduction of hydrocarbon fuel into the reformer. A hydrocarbon stream is introduced into the autothermal reformer following removal of the carbonaceous material. A concurrent supply of the hydrocarbon stream and the oxidant stream to the autothermal reformer is maintained such that an exothermic reaction driven by the oxidant stream provides heat to an endothermic reaction driven by water vapor added to the hydrocarbon stream.
[0003] In accordance with one embodiment of the present invention, a method of operating a fuel reforming system comprising an autothermal reformer is provided. According to the method, carbonaceous material is removed from a catalyst within the autothermal reformer and the temperature of the catalyst is increased by introducing an isolated oxidant stream into the autothermal reformer. The oxidant stream is substantially free of hydrocarbon fuel and water vapor and is introduced into the autothermal reformer when a temperature of the catalyst is low enough to ensure that heat generated from an exothermic reaction of the oxidant stream and the carbonaceous material is insufficient to raise the temperature of the catalyst above the maximum operating temperature T MAX of the catalyst. A hydrocarbon stream is introduced into the autothermal reformer following removal of a substantial portion of the carbonaceous material from the catalyst by the isolated oxidant stream. A concurrent supply of the hydrocarbon stream and the oxidant stream to the autothermal reformer is maintained such that an exothermic reaction driven by the oxidant stream provides heat to an endothermic reaction driven by the water vapor in the hydrocarbon stream. A hydrogenous gas product stream is generated from the exothermic and endothermic reactions.
[0004] In accordance with another embodiment of the present invention, a fuel reforming system comprising an autothermal reformer and a system controller is provided. The system controller is programmed to (i) affect removal of carbonaceous material from a catalyst within the autothermal reformer and increasing the temperature of the catalyst by causing an isolated oxidant stream to be introduced into the autothermal reformer, wherein the oxidant stream is introduced into the autothermal reformer when a temperature of the catalyst is low enough to ensure that heat generated from an exothermic reaction of the oxidant stream and the carbonaceous material is insufficient to raise the temperature of the catalyst above the maximum operating temperature T MAX of the catalyst; (ii) cause a hydrocarbon stream to be introduced into the autothermal reformer following removal of the carbonaceous material; and (iii) cause a concurrent supply of the hydrocarbon stream and the oxidant stream to the autothermal reformer to be maintained such that an exothermic reaction driven by the oxidant stream provides heat to an endothermic reaction driven by the water vapor in the hydrocarbon stream.
[0005] Additional embodiments of the present invention may be gleaned from the present specification.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
[0007] [0007]FIG. 1 is a schematic illustration of a fuel reforming system according to one embodiment of the present invention;
[0008] [0008]FIG. 2 is a graphic illustration of temperature changes of a catalyst utilized in a fuel reforming system according to one embodiment of the present invention; and
[0009] [0009]FIG. 3 is a schematic illustration of a vehicle employing a fuel reforming system according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0010] Referring now to FIG. 1, the present invention relates to a fuel reforming system 10 and a method of operating a fuel reforming system comprising an autothermal reformer 20 . As will be appreciated by those familiar with hydrocarbon reforming, autothermal reformers combine the processes of steam reforming and partial oxidation reforming. Further, steam reforming reactions are typically endothermic and partial oxidation reforming reactions are typically exothermic. Accordingly, the heat Q from the partial oxidation reforming reaction may be provided for the endothermal process of the steam reforming reaction.
[0011] The specific reformer configuration and catalyst criteria utilized in affecting steam reforming and partial oxidation reforming in the autothermal reactor 20 of the present invention are beyond the scope of the present invention. For example, by way of illustration and not limitation, the reformer may be configured to generate a hydrogenous gas product stream comprising H 2 and at least one of CO and CO 2 from a hydrocarbon stream.
[0012] For the purposes of describing and defining the present invention, it suffices to note that the respective reactions can be run in separate catalytic reactors in good thermal contact, in a single catalytic reactor, or in any other suitable manner. It is also noted that reference to a “catalyst” herein contemplates the use of a single element catalyst, a catalytic compound, a combination of independent catalytic compounds or elements, a plurality of independent catalyst elements or compounds, or any other suitable catalytic material.
[0013] The present inventors have recognized that autothermal reformer catalysts may be characterized by a number of different temperatures or temperature states. For example, the “light-off” temperature of a catalyst is the temperature at which the catalyst contributes to the reforming process, for example, by converting HC to desirable reactant products like CO 2 , CO and H 2 . The catalytic carbon bum off temperature of a catalyst is the temperature above which an carbon/oxygen exothermic reaction will be initiated by an oxidant passing over a carbon-contaminated catalyst. Referring to FIG. 2, reformer catalysts may also be characterized by a maximum operating temperature T MAX , i.e., a temperature above which the catalyst experiences significant physical damage or structural degradation or above which the catalyst ceases to operate effectively.
[0014] According to the present invention, carbonaceous material contaminating a reformer catalyst is removed from the catalyst within the autothermal reformer 20 by introducing an isolated oxidant stream 22 into the autothermal reformer 20 . The resulting exothermic reaction of the oxidant and the carbonaceous material results in removal of the carbonaceous material and increases the temperature of the catalyst, reducing some of the challenges associated with reformer start-up.
[0015] To ensure that the heat generated from the exothermic reaction of oxygen in the oxidant stream 22 and the carbonaceous material in the reformer 20 does not raise the temperature of the catalyst above its operating temperature, or above a temperature at which thermal damage to the catalyst would occur, the oxidant stream 22 is introduced into the autothermal reformer 20 when the temperature of the reformer catalyst is low enough to ensure that heat generated from an exothermic reaction of the oxidant stream and the carbonaceous material is insufficient to raise the temperature of the catalyst above the maximum operating temperature T MAX of the catalyst. The oxidant stream 22 may be introduced when the temperature of the reformer catalyst is above or below its catalytic light-off temperature. The temperature of the catalyst should be at least high enough to generate the carbon bum-off exotherm, i.e., at least as high as the catalytic carbon burn off temperature of the catalyst. In this manner, the isolated oxidant stream may be utilized to raise the temperature of the catalyst safely while removing carbonaceous material. Of course, it is contemplated that the oxidant stream 22 may be introduced when the temperature of the reformer catalyst is below the catalytic carbon bum off temperature of the catalyst, provided heat from the oxidant stream or some other source is able to raise the temperature of the catalyst above the catalytic carbon bum off temperature.
[0016] The present inventors have recognized that care must be taken to ensure that the heat Q EX generated by the exothermic reaction of the oxygen and the carbonaceous material 20 will not raise the temperature of the catalyst above T MAX . If the exothermic reaction is initiated during operation, at shut-down, immediately following shut-down, or at any other time when the catalyst is near the operating temperature of the reformer 20 T OP , the heat Q EX generated by the exothermic reaction will be more likely to raise the temperature of the catalyst above T MAX than it would be if the exothermic reaction were initiated prior to introduction of hydrocarbon fuel into the reformer, near a relatively cool temperature state T COLD of the reformer 20 . FIG. 2 illustrates initiation of the exothermic reaction at these two different temperatures and shows how the temperature of the catalyst can be maintained below T MAX despite the increase in temperature attributable to the heat Q EX generated by the exotherm.
[0017] For example, the temperature of the catalyst may be maintained below T MAX by introducing the isolated oxidant stream 22 into the autothermal reformer 20 as part of a start-up sequence of the fuel reforming system 10 because the temperature of the catalyst is typically near T COLD at start-up. Although preferred temperatures for introduction of the isolated oxidant stream will vary greatly depending upon the nature of the reformer catalyst and the fuel to be reformed, in some embodiments of the present invention the isolated oxidant stream 20 may be introduced into the autothermal reformer at any time when the temperature of the catalyst is between about 200° C. and about 600° C. or, more commonly, between about 300° C. and about 500° C. The isolated oxidant stream 22 may comprise a substantially pure oxygen stream, a combination of oxygen and an inert gas, or a gaseous mixture, such as air, that includes oxygen. The isolated oxidant stream 22 may be provided such that it is substantially free of hydrocarbon fuel and water vapor. It is contemplated, however, that there may be system reasons to include water vapor in the oxidant stream, particularly where it can be considered inert, i.e., where the catalyst has not reached its catalytic light of temperature.
[0018] A hydrocarbon stream 24 , typically comprising a hydrocarbon fuel to be reformed and water vapor, is introduced into the autothermal reformer 20 following removal of a substantial portion, a majority, or substantially all of the carbonaceous material from the catalyst by the isolated oxidant stream. In this manner, the operational efficiency and effectiveness of the autothermal reformer 20 may be optimized. It is noted that the desired extent of removal of the carbonaceous material will depend upon the operational preferences of those practicing the present invention. To further optimize the efficiency and the effectiveness of the hydrocarbon reforming process, the hydrocarbon fuel is typically not introduced into the reformer until after the catalyst reaches or exceeds its catalytic light-off temperature. Of course, instances are contemplated where such a condition need not be followed.
[0019] As is illustrated in FIG. 1, it is noted that the hydrocarbon stream 24 , comprises hydrocarbons and water vapor. Typically, a significant amount of water vapor is added to the hydrocarbon stream, usually as a separate stream. It is contemplated that the hydrocarbon stream 24 may be provided from a single source or separate sources—one providing the hydrocarbon and the other providing the water vapor. In some embodiments of the present invention, it may be preferable to select a catalyst that is non-pyrophoric and is configured to contribute to reformation of hydrocarbon fuels in an initially oxidized state.
[0020] Typically, a concurrent supply of the hydrocarbon stream and the oxidant stream to the autothermal reformer are maintained such that the exothermic reaction driven by the oxidant stream provides heat to the endothermic reaction driven by the water vapor in the hydrocarbon stream. The resulting exothermic and endothermic reactions lead to generation of a hydrogenous gas product stream 25 at the output of the reformer 20 .
[0021] A programmable system controller 26 and an input flow controller 28 may be provided for controlling the manner in which the oxidant and hydrocarbon streams 22 , 24 are supplied to the reformer 20 . It is contemplated that suitable equipment like power supplies, user interfaces, temperature sensors, flow meters, particulate matter sensors, etc., may be provided to complement the operations of the programmable controller 26 .
[0022] As is illustrated in FIG. 1, it may be preferable to direct the gas product stream 25 to a water-gas shift reactor 26 configured to convert CO and H 2 O to CO 2 and H 2 , particularly where the gas product stream 25 contains significant amounts of CO and H 2 O. Similarly, it is contemplated that alternative or additional upstream or downstream filters, reformers, or other fuel processing elements may be included in the fuel reforming system of the present invention.
[0023] Referring now to FIG. 3, it is noted that fuel reforming systems 10 of the present invention may be configured to operate as part of a fuel reforming unit 11 of a vehicle 50 . Specifically, a reformed gas product stream from the fuel reforming unit 11 may be directed to a fuel cell assembly 30 configured to convert reformed fuel, e.g., H 2 , into electricity. The electricity generated is subsequently used a motive power supply for the vehicle 50 where the electricity is converted to torque and vehicular translational motion.
[0024] It is noted that terms like “preferably,” “commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.
[0025] For the purposes of describing and defining the present invention, it is noted that the terms “substantially” and “about” are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms “substantially” and “about” are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
[0026] Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.
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Carbonaceous material is removed from a catalyst within an autothermal reformer by introducing an isolated oxidant stream into the autothermal reformer prior to introduction of hydrocarbon fuel into the reformer. A hydrocarbon stream is introduced into the autothermal reformer following removal of the carbonaceous material. A concurrent supply of the hydrocarbon stream and the oxidant stream to the autothermal reformer is maintained such that an exothermic reaction driven by the oxidant stream provides heat to an endothermic reaction driven by water vapor in the hydrocarbon stream. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. application Ser. No. 10/429,372, filed on May 5, 2003, incorporated by reference herein.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable.
FIELD OF THE INVENTION
[0004] The invention disclosed broadly relates to the field of computer systems, and more particularly relates to the field of wearable personal computing devices.
BACKGROUND OF THE INVENTION
[0005] In today's busy world, shoppers look to technology for ways to make the shopping experience easier, faster and more secure. Stores look to technology to lower the high cost of sales transactions which is directly attributable to the increasingly high cost of hiring and paying employees. Therefore, there is a need for greater automation of the purchase and sales transaction process. Credit cards and debit cards are now the methods of payment favored by many shoppers over cash because of the convenience and also because many shoppers are hesitant to carry large amounts of cash. As today's commerce moves toward a paper-less transactional paradigm, the traditional shopping list hand-written on a sheet of paper has evolved into a list digitally stored in a handheld computer. These conveniences have improved the shopping experience to a certain level, but many inconveniences remain in the shopping experience. Since most of the buying public cannot afford a personal shopper there are still many drawbacks inherent in the shopping experience which need to be addressed.
[0006] One such drawback is the necessity of carrying and handling methods of payment, such as credit cards. Consider a shopper on a shopping excursion during a busy holiday weekend and assume that this shopper intends to pay for purchases with department store credit cards. Every purchase made by the shopper involves removing the credit card from a wallet after first removing the wallet from a purse or trouser pocket. Then, after the transaction is finalized with the credit card, requiring the shopper's signature, the shopper needs to replace the card back in the wallet. Consider a shopper performing this ritual several times over the course of a shopping expedition, each time loaded down with more and more bags of purchases. The potential for misplacing the credit cards or the purchases increases with each transaction. In addition, this same shopper has to be constantly vigilant that no one will steal the purchases, the credit cards, or even the shopper's wallet or purse.
[0007] Credit card purchases also generate paper in the form of receipts. The shopper has to properly store the receipts, which are easy to misplace. Many shoppers do not want to carry receipts because of the fear that someone could appropriate the receipt and copy a signature or credit card number from the receipt. This is why many gasoline station payment systems do not print a receipt unless the customer asks for one.
[0008] Finding the desired items in a crowded store can be a considerable chore. Assume that the shopper is looking for clothing items and assume also that this shopper is constrained by a budget, as are most shoppers. The shopper needs to first find the desired apparel in the correct size and then check the price of the item. This is not easily accomplished in a crowded store where a shopper needs to check tags on items hanging very close together on racks. Sometimes a shopper has to remove dozens of items from clothing racks in order to find and read the size and price tags in search of the desired garment.
[0009] The increasing popularity of purchasing items online has created a need for security measures. One of these is public key encryption. This technology makes it possible for persons purchasing items from an internet site to provide their credit information in a secure manner by using encryption. The technology also provides means for the store to make sure that authorizations for payment are received from the person who purports to send it. There also exists technology for determining whether anyone has tampered with a digital payment authorization message.
[0010] There is therefore a need for a device which can overcome the preceding drawbacks and shortcomings in the prior art while preserving secure purchase communications.
DEFINITION OF TERMS
[0011] Some key terms are defined here. The definitions listed here are from the Computer Desktop Encyclopedia , Copyright© 1981-2001, The Computer Language Company, Inc.
[0012] Barcode—The printed code used for recognition by a bar code scanner (reader). Traditional one-dimensional bar codes use the bar's width to encode just a product or account number. Two-dimensional bar codes, such as PDF417, MaxiCode and DataMatrix, are scanned horizontally and vertically and hold considerably more data. PDF417 is widely used for general purposes. MaxiCode is used for high-speed sortation, and DataMatrix is used for marking small parts.
[0013] Bar code scanner—A device specialized for reading bar codes and converting them into either the ASCII or EBCDIC digital character code. In order to be read, the tip of the pen must physically touch the bar code. Later, laser scanners allowed the bar code to be read at a slight distance from the head of the device, enabling supermarkets to read round cans and flexible packages more easily. The most common of that type today is the visible laser diode (VLD) scanner, which emits as many as 50 laser beams simultaneously to capture the image at any angle.
[0014] Certificate—a certificate contains the public key for the person or entity to which the certificate is issued. The certificate is signed by a trusted party such as VeriSign. The signature helps in making a trusted association between the entity and the public key.
[0015] Digital Signature—A digital signature, or e-signature, is a sequence of bytes that is appended to an electronic document that can be used to verify the identity of the person signing the document, and also that the document has not been modified since it was signed.
[0016] Liquid Crystal Display (LCD)—A display technology that uses rod-shaped molecules (liquid crystals) that flow like liquid and bend light. Un-energized, the crystals direct light through two polarizing filters, allowing a natural background color to show. When energized, they redirect the light to be absorbed in one of the polarizers, causing the dark appearance of crossed polarizers to show. The more the molecules are twisted, the better the contrast and viewing angle. Because it takes less power to move molecules than to energize a light-emitting device, LCDs replaced LEDs in digital watches years ago.
[0017] LED—(Light Emitting Diode) A display technology that uses a semiconductor diode that emits light when charged. It usually gives off a red glow, although other colors can be generated. It is used in readouts and on/off lights in a myriad of electronic appliances. It was the first digital watch display, but was superseded by LCD, which uses less power. LEDs are also used as a light source for fiber-optic transmission. They are typically used with lower-bandwidth multimode fibers.
[0018] PDF417 (Portable Data File417). A two-dimensional bar code that was created in the late 1980s, the standard was later placed in the public domain and is governed by the Automatic Identification Manufacturers (AIM) trade association. The PDF417 can hold up to 1,800 bytes of any digital data in a printed area about the size of a business card.
[0019] Point of sale terminals: Capturing data at the time and place of sale. Point of sale systems use personal computers or specialized terminals that are combined with cash registers, bar code readers, optical scanners and magnetic stripe readers for accurately and instantly capturing the transaction. Point of sale systems may be online to a central computer for credit checking and inventory updating, or they may be stand-alone machines that store the daily transactions until they can be delivered or transmitted to the main computer for processing.
[0020] Private key is defined as: The private part of a two-part, public key cryptography system. The private key is kept secret and never transmitted over a network.
[0021] Public key is defined as: The published part of a two-part, public key cryptography system. The private part is known only to the owner.
[0022] Public key cryptography: A cryptographic method that uses a two-part key (code) that is made up of public and private components. To encrypt messages, the published public keys of the recipients are used. To decrypt the messages, the recipients use their unpublished private keys known only to them.
[0023] SKU—(StockKeeping Unit) The number of one specific product available for sale.
SUMMARY OF THE INVENTION
[0024] Briefly, according to a claimed invention, a method for selling an item in a shopping venue includes steps of: receiving a signal from a mobile information processing device, the signal including a list of items of interest; and transmitting a signal indicating the location of the item of interest in the store to the mobile information processing device.
[0025] According to another embodiment of the claimed invention, a method for selling items by a vendor in a shopping mall includes steps of: receiving a first signal from a mobile information processing device, the first signal including information that includes a list of items of interest; and transmitting a second signal indicating the price and location of items of interest from the list to the mobile information processing device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is an illustration of a sales transaction system according to an embodiment of the invention.
[0027] FIG. 1A is a view of the back of a portable intelligent shopping device, according to an embodiment of the invention.
[0028] FIG. 2 is a data flow diagram of a purchase and sale transaction, according to an embodiment of the invention.
[0029] FIG. 3 is a block diagram of a portable intelligent shopping device, according to an embodiment of the invention.
[0030] FIG. 4 is an illustration of the top view of a portable intelligent shopping device displaying a price, according to an embodiment of the invention.
[0031] FIG. 5 is an illustration of the portable intelligent shopping device worn on a belt, according to an embodiment of the invention.
[0032] FIG. 6 is an illustration of a side view of the portable intelligent shopping device worn on a belt, according to an embodiment of the invention.
[0033] FIG. 7 is an illustration of the size selection feature of the portable shopping device, according to an embodiment of the invention.
[0034] FIG. 8 is an illustration of the grocery shopping list feature of the portable shopping device, according to an embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] According to a preferred embodiment, a small, lightweight, wearable intelligent device of varying form factors assists shoppers in selecting and purchasing desired items. This assistance is in the form of a secure and automated performance of paper-less purchase and sale transactions.
[0036] Referring to FIG. 1 , an automatic and secure purchase and sale transaction system 100 according to an embodiment of the invention comprises a Portable Shopping Device 101 and a Store Terminal 120 that communicate with each other to perform a paper-less transaction.
[0037] The Portable Shopping Device (PSD) 101 is an information processing system that is preferably a small lightweight device suitable to be worn on a shopper's wrist or carried in a shirt pocket or attached to a belt or lanyard. In the example shown in FIG. 1 , the PSD 101 uses a wrist watch form factor for convenient mobility. It preferably comprises a high definition display 112 , preferably with a touch-sensitive screen, and a scrolling wheel input device 114 , as described in commonly-owned U.S. Pat. No. 6,525,997 B1 “EFFICIENT USE OF DISPLAY REAL-ESTATE IN A WRIST WATCH DISPLAY” and “Application Design for a Smart Watch with a High Resolution Display” by Chandra Narayanaswami and M. T. Raghunath, both of which are incorporated by reference as if fully set forth herein. The display screen 112 is shown displaying the time and a bar code 104 . The bar code 104 represents purchase item information according to one embodiment of the invention. On the top and bottom of the watch casing are shown retractable bars 118 through which a watch strap 113 is threaded.
[0038] The second component of the sales transaction system 100 is the Store Terminal 120 which is a point of sale terminal, similar to those found in any major department store but adapted to operate according to embodiments of the invention. The Store Terminal 120 in this embodiment comprises a wireless interface 121 , a processor 123 , a read subsystem 125 and memory 127 . Connected to the read subsystem 125 is a bar code reader 122 (also known as a bar code scanner) for reading the bar code 104 on the PSD 101 . The double-headed arrow 130 represents signals, such as short-range Radio Frequency (RF) or Infra-Red (IR) signals, for transmitting data to enable a wireless purchase transaction.
[0039] The compact size and lightness of the PSD 101 make it ideal to be worn as a wristwatch. Other form factors are also contemplated within the spirit of the invention, such as a belt accessory, but for purposes of this example we will focus our discussion on the wristwatch form factor.
[0040] FIG. 2 illustrates the operation of the sales transaction system 100 with respect to a purchase and sale transaction in a department store. The actions performed by the PSD 101 are shown on the left and the actions performed by the Store Terminal 120 are shown on the right. The sales transaction system 100 operates as follows. In step 201 a user, wearing the PSD 101 , selects an item for purchase and brings the item to the Store Terminal 120 . A method according to an embodiment of the invention for selecting an item for purchase is discussed below with reference to FIG. 7 . The PSD 101 will communicate to the Store Terminal 120 , preferably via wireless transmission, that it requires the store's certificate in order to commence a transaction.
[0041] In step 203 , the Store Terminal 120 , in response to a transmission from the PSD 101 , presents the store's certificate to the user. For purposes of the discussions to follow we will refer to the user of the PSD 101 as a shopper. This transmission from the Store Terminal 120 can also be done via an encrypted wireless transmission protocol. In step 205 the PSD 101 checks the certificate to verify that it originated from a valid Store Terminal 120 . The certificate is issued by a trusted third party service organization, such as VeriSign. The PSD 101 uses VeriSign's public key to verify VeriSign's signature on the certificate.
[0042] The PSD 101 may already have the store's public key stored in its memory 127 or may receive it at this time. The Store Terminal 120 may have already sent the store's public key to the PSD 101 in step 203 .
[0043] In step 207 , the price of the item for purchase and its identifying information, such as the SKU, are input to the Store Terminal 120 through conventional means, perhaps by a sales clerk scanning the price tag. The Store Terminal 120 , after receiving the item identifier and amount, transmits a request for payment authorization of the selected item by providing a signal to the PSD 101 preferably via an appropriate communication medium, such as IR or RF transmission. The signal comprises a price for the item and an identification of the item by known means such as a displayed written description. This request for payment is preferably encrypted by the Store Terminal 120 with the store's private key and the shopper's public key. This encryption is essential to assure the shopper that the request for payment, which will include a request for form of payment, such as a credit card number, originates from the Store Terminal 120 and not someone trying to steal a credit card number.
[0044] Next, in step 209 , the PSD 101 presents the received information to the shopper, in response to receiving the request for payment authorization from the Store Terminal 120 . Since this message requesting payment from the Store Terminal 120 is encrypted, the PSD 101 will decrypt the message using the shopper's private key and the enclosed certificate is decrypted with the store's public key. This message, which contains the price of the item, can be presented to the shopper in the form of a text message on the display 112 or perhaps in the form of an audio message.
[0045] At this time, the shopper can also be prompted to enter his or her personal identification code (e.g., a number or PIN) in order to validate the request for payment. This is a security feature to prevent someone who has stolen the PSD 101 from using it to make unauthorized purchases.
[0046] The PSD 101 will confirm the PIN entered, and if it is valid, in step 211 the PSD 101 generates a message authorizing payment, including an account number or credit/debit card number, for the selected item, which needs to be encrypted for security purposes. The PSD 101 then appends an e-signature to the message that includes an amount and the card or account number. The message also preferably includes an interjacence counter-measure, such as a hash function performed on the message to generate a message digest. The signed payment authorization is encrypted using a suitable encryption scheme to protect the communication from eavesdroppers. Such an encryption scheme can be implemented by programming the PSD 101 with an algorithm stored in memory 127 for execution by the processor 123 , or by an application-specific integrated circuit comprising the appropriate algorithms.
[0047] In step 213 the Store Terminal verifies the shopper's e-signature in the payment authorization and accepts the e-signature in lieu of a paper signature. Since the message included a form of payment, such as a credit card number, the next step 215 involves the Store Terminal 120 processing the purchase using conventional means, such as contacting the credit card agency and transmitting the purchase price to be credited to the shopper's credit card.
[0048] If the store does not have a device that can communicate with the PSD 101 using IR or RF signals the method works as follows. The store clerk orally tells the shopper the amount due. The shopper enters the payment amount into the watch along with his/her PIN. Once this is done, the PSD 101 creates a payment authorization message that includes the payment authorization amount and credit card or store account information. The PSD 101 then signs the message as discussed above. It then encodes a payment message and shopper's certificate, preferably as a 2-dimensional bar code 104 for display on the PSD 101 display screen 112 . The store can scan the bar code 104 clearly displayed on the display screen 112 of the PSD 101 with a bar code reader 122 and verify it as above. Since the device has a very high resolution display, for example 600 dots per inch (600 dpi), it can be used to convey a large amount of information on a screen using a 2D barcode. The amount of information which can be stored on a 2D barcode is more than a hundred bytes.
[0049] If the store does not have a 2D bar code reader, the watch can be used to send the same message using a sequence of one-dimensional (1D) bar codes. Most stores have 1D barcode readers which can be easily retrofitted to read a bar code displayed on a shopper's PSD 101 .
[0050] In step 217 a receipt for the purchase and sale transaction is generated by the Store Terminal 120 . This receipt can be generated through conventional means, such as a paper receipt, or, as an optional alternative to a paper receipt, the Store Terminal 120 could generate an electronic receipt. This electronic receipt could be encrypted by the store with the shopper's public key and transmitted to the PSD 101 . The PSD 101 would then decrypt it with its private key and store it. This is an optional alternative to receiving a paper receipt.
[0051] The display 112 has several modes, which can be selected by using the roller wheel 114 or other input device, such as the touch screen, as more fully described in commonly-owned U.S. Pat. No. 6,525,997 B1 “EFFICIENT USE OF DISPLAY REAL ESTATE IN A WRIST WATCH DISPLAY” and also in the publication “Application Design for a Smart Watch with a High Resolution Display” by Chandra Narayanaswami and M. T. Raghunath. In bar code mode, the display 112 shows the bar code of the selected/purchased item, and optionally displays the current time. When in bar code mode, the shopper presents the PSD 101 display screen 112 to a sales clerk in order for the sales clerk to scan the bar code 104 using a bar code reader 122 . Optionally, the information can be scanned by the shopper.
[0052] In price mode, the display 112 shows the price of the selected item, but in place of the current time, the user sees an accept/reject icon. A user of the PSD 101 can accept a price by any of several ways such as tapping or clicking on an accept command displayed on the screen 112 .
[0053] In the above-discussed example the shopper uses credit card information to authorize payment but it should be understood that other means of payment authorization can also be used. For example, the shopper could use digital tokens that are analogous to physical tokens that can be purchased for later payment for items of interest.
[0054] Referring to FIG. 3 we show a block diagram of the portable shopping device 101 showing a highly simplified version of the key internal components. The memory block 301 stores a private key 303 , a certificate 305 and user preferences 307 . The memory 301 is connected to a system processor 308 and an Input/Output subsystem 310 . The I/O subsystem, containing a display driver 320 , is in turn connected to the user interface which is the display 112 and to an antenna for transmission of signals to store terminals. The display 112 is shown displaying a bar code and the time. The memory 301 can be a semiconductor memory such as a flash EPROM (erasable, programmable, read-only memory), a small hard disk drive, or any other suitable information storage device. The logic performed according to the invention can be realized with either an application-specific integrated circuit (ASIC) or a general-purpose processor and instructions embedded in Read Only Memory (ROM) or other storage for performance by the processor.
[0055] FIG. 4 shows a close-up top view of the PSD 101 with the display in “price” mode. The display 112 shows the price of the item selected for purchase. At the bottom of the display window there is a button 401 for accepting or declining the purchase. The arrow icons around the display screen represent directions for scrolling the content displayed on the screen and for toggling back and forth among display modes, such as price mode (displaying an item price) and bar code mode (displaying purchase item information for scanning). It should be understood that other icons can also be used to represent functions and functions other than scrolling and toggling are possible within the spirit and scope of the invention, as described in “Application Design for a Smart Watch with a High Resolution Display” by Chandra Narayanaswami and M. T. Raghunath.
[0056] FIG. 5 shows another embodiment wherein the PSD 101 is attached by a belt clip 510 and worn on a belt 501 . This embodiment is more convenient for PSD 101 models that are bigger or heavier than may be comfortably worn on a wrist.
[0057] FIG. 6 is a side view of the PSD 101 disposed in the belt clip 510 . As can be seen from this illustration, the PSD 101 can be easily removed from the belt clip 510 and carried by hand or in an alternative embodiment, it can be attached to a lanyard or key ring. A wrist-worn PSD 101 can be modified to be worn on a belt by retracting the watch strap bars 118 into grooves on the back casing. The grooves are represented by the cross-hatched boxes.
[0058] Referring to FIG. 7 , there is shown a PSD 101 with additional optional features of memory and logic for storing a shopper's size, color and/or price preferences. The PSD 101 can be configured to transmit a shopper's preferences by means of a short-range transmitter so that when a shopper wearing the PSD 101 approaches a rack of clothing all of the clothes that match the shopper's preferences light up responsive to receiving the transmission comprising the preferences. The short range transmissions can be accomplished by transmission of a periodic low power radio (or other medium) signal comprising the shopper's preferences. Once a store wireless terminal receives the signals, it identifies the matching items and causes a location indicator such as a light 710 or sound to alert the shopper of the sought item's location.
[0059] For example, in one embodiment of the invention a shopper would key in his/her size preference into the PSD 101 using a keypad 702 . Assume that the shopper wishes to select clothing that is size 2. The shopper would key this information into the keypad 702 . In the store, the clothes hangers on the clothes rack are equipped with small Light Emitting Diodes (LEDs) 710 located on the upper portion of the hanger where it would not be obscured by the attached garment. The PSD 101 transmits the shopper's size preference to the clothes rack by means of a periodic or constant radio signal comprising the shopper's size preferences. The signal is preferably a short-range signal so that the transmission strength of the signal is strong enough to be received by the clothes rack only when the shopper is near enough to the clothes rack to be able to see it.
[0060] Alternatively, the signal could be received directly by the LEDs attached to the clothes hangers. The LEDs attached to the hangers that match that size light up with a blinking light, preferably a red blinking light. Only the hangers displaying size 2 clothing would light up, therefore the shopper would know at a glance which clothing items to inspect. The shopper would not have to pick up each item and search for a size tag. In an alternative embodiment, the LEDs could be attached to the clothing items or a tag 716 hanging from the clothing items.
[0061] In another embodiment the LED could light up with a display 714 of a shopper's name, nickname, or code word in order to distinguish a particular shopper's desired item from that of a nearby shopper concurrently transmitting a size selection for a different size.
[0062] This principle is extensible to other concepts. Assume a grocery shopper keys in or downloads a grocery shopping list to the PSD 101 . When in an aisle in a grocery store, tags light up near the items that a shopper wearing a PSD 101 has identified in his shopping list in the PSD 101 . User preferences, such as the grocery shopping list, can be entered into the PSD 101 by connecting it to a docking station or connector attached to a personal computer. Only the items in the grocery list which are located in close proximity to the shopper wearing the PSD 101 would light up.
[0063] The range of distance between the PSD 101 and the item which lights up has to be pre-selected by the individual store and this selection will most probably be based on the type and size of the store. For example, in a large supermarket where a shopper can easily see most items along an entire aisle of the supermarket, the range can be set to encompass the length and breadth of the grocery aisle. In a small, crowded boutique or a small department within a department store where a shopper has a limited range of vision, the range can be set to a circle with a diameter not to exceed six feet. When the shopper is within range, the items selected by the PSD 101 will light up and then when the shopper moves out of range, the lit items turn off.
[0064] FIG. 8 shows a PSD 101 in wristwatch form factor and a sample representation of a cereal aisle 800 in a grocery store. As shown in FIG. 8 , electronic tags 820 placed near the desired items from the shopper's list will light up, perhaps with a flashing light, when the shopper is near enough to the desired items (in this case, a desired cereal brand) to be alerted by the lights. The shopping list could be downloaded from the shopper's computer or personal digital assistant (PDA).
[0065] In addition to sending a signal to flag the desired items, the PSD 101 could also download an electronic route map of the grocery store and then, using this route map, rearrange the shopping list items so that they track the aisles in the grocery store, according to the route map. For example, assuming a shopper begins grocery shopping in aisle 1 and then proceeds through the store until the last aisle, the shopping list would be rearranged so that all of the aisle 1 items are listed first, then the aisle 2 items, etc. The items would light up when the PSD 101 is in close proximity to them, aisle by aisle. The list could be recomputed dynamically if the shopper sees something not on the list and decides to go get it, thereby deviating from the set route. For example, if a shopper is in aisle 3 and instead of proceeding to aisle 4 goes directly to the produce section in the back of the store near aisle 7 , the PSD 101 will rearrange, or sort, the items on the grocery list to originate with the items closest to the produce section.
[0066] Optionally, a shopper could delete or tag items on the grocery list as they are picked, similar to a shopper drawing a line through items on a paper list. This can be done by tapping on the touch screen where the item name appears, perhaps with a stylus, or by using the rotating wheel 114 as a scroller to highlight an item for deletion and then depressing the wheel 114 to select the item. Highlighting and selecting items on a wrist watch display are known to those skilled in the art and are discussed in U.S. Pat. No. 6,525,997 B1 “EFFICIENT USE OF DISPLAY REAL-ESTATE IN A WRIST WATCH DISPLAY” and “Application Design for a Smart Watch with a High Resolution Display” by Chandra Narayanaswami and M. T. Raghunath.
[0067] An additional feature would be to provide an option for ordering of the shopping list other than by the location of items, such as sorting a list beginning with non-perishable foods and ending with frozen foods. Many grocery shoppers, especially those buying a large load of groceries, prefer to get the frozen foods (designated as the most perishable) last.
[0068] In another embodiment and use of the PSD 101 , mall stores broadcast their specials and the device can receive these broadcasts and alert the shopper when a desired item is on sale nearby. The shopper has no need to transmit information about what items and/or sizes the shopper desires. There is no necessity for transmits from the shopper's PSD 101 . In this embodiment, the device stores an identification of at least one desired item and the mall stores broadcast their specials. If one of the broadcasted specials matches an item in the shopper's list within the PSD 101 , the device alerts the shopper. The alert could be in the form of an alarm or a flashing light on the display 112 of the PSD 101 . Watch alarms and flashing light displays are both known and used in wrist watch technology today.
[0069] In a shopping mall, the PSD 101 can also keep track of the best broadcasted price for an item and act as a best-price finder for a particular item. Assume the shopper is traversing a typical large suburban mall where many of the stores stock the same items. The shopper introduces the item of interest into the PSD 101 and walks through the mall. The stores are broadcasting items with their respective prices (similar to the broadcast technology used in cellular telephone communication). The PSD 101 will only store the broadcast which matches the desired item input by the shopper. Assume many of the stores in this mall are broadcasting the same item, but with different prices. The PSD 101 will store all of these broadcasts and automatically sort the list in order from lowest to highest price. A quick glance at the list informs the shopper of the best price for the desired item.
[0070] In a similar embodiment, a shopper performs reverse auctions using the PSD 101 device. For example, at a mall the PSD 101 sends out an offering bid for an item that the shopper wants to buy. All stores in the mall that are properly equipped receive the bid and respond with “yes/no/best offer” transmissions. If the shopper does not like any offer made by the merchants he or she can go buy the item elsewhere. On the other hand, if a favorable response is received from one or more merchants, the user can proceed to purchase the item or negotiate further.
[0071] The examples and illustrations discussed above are meant to represent some of the ways in which the instant invention can be advantageously used to facilitate purchase and sale transactions in a secure manner. Those skilled in the art will perceive that the examples discussed above are by no means comprehensive, but instead are a representative sampling of the possible embodiments of the instant invention.
[0072] Therefore, while there has been described what are presently considered to be the preferred embodiments, it will be understood by those skilled in the art that other modifications can be made within the spirit and scope of the invention.
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A method for selling items by a vendor in a shopping venue includes steps of: receiving a first signal from a mobile information processing device, the signal including a list of items of interest; and transmitting a second to the mobile information processing device, the second signal indicating that at least one of the items of interest from the list is available in the shopping venue.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a method for producing dough pieces which can be stored for a long period of time.
[0002] Dough pieces of this type are in particular yeast dough pieces such as dough pieces for bread or croissants which can be raw, prebaked or at least half-baked, as well as pastry dough pieces.
[0003] “Which can be stored for a long period of time” means that the dough pieces must remain usable for at least eight weeks, preferably 12 weeks, without the appearance of any quality deficiencies in the finished baked product.
[0004] Frozen storage has proven to be successful with small dough pieces for pastry products and small baked goods. However, it has not been possible to store frozen dough pieces that weigh 500 g or more without major compromises in quality.
[0005] Controlled cooling thereby has a whole series of undeniable advantages for bakers who do the final baking locally. The production and baking times can be rendered independent of each other by the use of refrigeration, larger batches can be prepared and products that can be baked fresh on demand make it possible to optimally satisfy the most important of all customer wishes. These advantages are explained in greater detail below in the context of an examination of baking and logistics systems in current use.
[0006] The increasing cost and complexity of production are strengthening the position of pre-bake stations and bakery discounters that pre-bake industrially produced baked goods, so that the half-baked goods can be reheated in front of the customer. These breads are baked until they are almost finished and need to be baked again locally only until they are browned. The availability of hot baked goods gives the illusion of freshness and hand-made products. The result, however, is baked goods that can be sold cheaply only at the expense of quality. The repeated baking of baked goods results in, among other things, an enormous loss of moisture which leaves the products dried out. The alternative, which is to bake the products in a central bakery and then ship them, results in a solution where the baked goods are not always available where and when they may be needed and also suffer a noticeable loss in quality after only a few hours.
[0007] The product quality can be significantly improved and continuously ensured by a precise monitoring and control of all of the important parameters in the climate-control process, even with very large quantities of product. In the interest of producing high-quality baked goods, the moisture content and the movement of the air must be monitored and controlled, in addition to the temperature and time, during the cooling, frosting and thawing. Time is a particularly critical variable during cooling and even more during frosting.
[0008] If a dough piece is cooled to temperatures for frozen storage, i.e. below −18° C., the process normally consists of three phases of cooling, in which entirely different amounts of energy are required to continue the cooling process. The physics of the freezing process are described, for example, in the article entitled “Bäckerkälte: Das richtige Klima macht die Qualität [Freezing for bakers: The right conditions ensure quality”] at http:/www.webbaecker.de/r-branche/2003/0303profikaelte.htm.
[0009] In a first cooling phase, the dough piece is cooled from room temperature to just above the specific freezing point of the dough piece. With doughs that contain fats, salts, minerals and other ingredients in addition to water, the freezing point is lower than that of pure water, namely approximately −7° C. In the remainder of this application, this temperature is designated the specific freezing point of the dough piece. Approximately 35% of the total cooling energy is used for this first phase.
[0010] The phase transition of the water bound in the dough piece from liquid to solid takes place in the second cooling phase and consumes a proportion of approximately 55% of the total cooling energy. The more rapidly the dough piece is cooled and in particular chilled all the way through in this phase, the better the baked result. “Shock freezing” ensures a particularly fine crystal structure in the baked good, without thereby destroying enzymes and the structure. While that does not represent a problem with small dough pieces, shock freezing generally is not successful with large-volume bread dough pieces because it later leads to an unsatisfactory baked result.
[0011] Finally, in a third cooling phase, the dough pieces are cooled even further to the storage temperature. Only 10% of the total cooling energy required is used for this phase.
SUMMARY OF THE INVENTION
[0012] The invention relates in particular to improvements in the first and second cooling phases. In spite of the relatively slight cooling of only a few degrees Celsius that takes place, these phases normally consume much more than half of the cooling energy required.
[0013] The object of the invention is therefore a method for the production of dough pieces that are suitable for long-term storage which ensures that the dough piece is rapidly cooled and which also ensures an effective chilling all the way through. That is important in particular when larger dough pieces, e.g. pieces of bread dough weighing more than 500 g, must be handled.
[0014] This object is accomplished by the method described in claim 1 . The invention teaches that the dough pieces are placed in a climate-controlled room in which a relative humidity of 100% has been established, and into which water is atomized at a droplet size <10 μm. The temperature of the room is lowered and the lowered temperature is maintained until the core temperature of the dough piece is below the specific freezing point of the dough piece.
[0015] The use of a water fog with a droplet size <10 μm for the production of unfinished baked goods is known. For example, EP 1 941 800 A2 describes the essentially homogeneous moistening of the respective unfinished baked product all the way through by circulating air around the unfinished baked product, so that the micro-droplets of water penetrate into the respective unfinished baked product so that there is an essentially uniform and thorough moistening of the individual unfinished product all the way through. The aerosol is thereby produced by means of an ultrasound atomizer, whereby the high-purity water used has previously been freed of microorganisms, lime and salts in a reverse osmosis plant. The increase of the relative humidity by the technique described in this prior art document as ultrasound climate control takes place in a freezing phase at −18° C., which is followed by a storage phase at −10° C. and a thawing phase at +1 to 3° C. The aerosol ensures that there is moisture on the surface of the frozen product.
[0016] FR 2 852 205 A describes a method for the preparation of fermentable food products by circulating air which includes at least one storage phase of the products during the cooling, while cooled cold air is circulated, in particular to interrupt the fermentation of the products, and a phase for treatment with wetting/warming, in which warm and moist air is circulated. During this wetting/warming phase, the
[0000] circulating air is moistened with a moistening aerosol generated by an ultrasound generator.
[0017] The invention does not use the aerosol to establish a uniform moistening of the respective dough piece all the way through, which is already achieved during the preparatory steps of the production of the dough piece. It has in fact been found that no measurable quantity of moisture is absorbed from the aerosol atmosphere. On a bread dough piece weighing 1000 g, a moisture absorption of 3% would correspond to a measurable weight increase of 30 g, although no such weight increase has ever been observed.
[0018] It has been determined, however, that the presence of the aerosol significantly improves the hot-to-cold transition of the dough piece. This can be confirmed by conductivity measurements. The treatment times can thereby be significantly shortened. This method also eliminates problems that are normally involved with the condensation of moisture at falling temperatures.
[0019] Because the core temperature of the dough pieces is also used as a reference for the control of the temperature of the room, this method ensures that the dough piece is optimally frozen through.
[0020] In one advantageous development of the method claimed by the invention, the dough pieces are fermented for a predetermined length of time at a temperature of 15° C. to 20° C. before the room temperature is lowered. Fermentation at these relatively low temperatures ensures that for further cooling, the dough pieces do not need to be cooled from a comparatively high temperature of 32° C. to 35° C., as is conventional in the prior art, which ensures a significant energy saving. The reduced fermentation temperature of 15° C. to 20° C. combined with the extended fermentation period also has advantages in terms of quality, as explained in greater detail below.
[0021] It is further advantageous, during the lowering of the temperature of the room, to include at least one plateau phase during which the temperature is kept constant, and during which the aerosol is regenerated if necessary. The method claimed by the invention employs relatively low cooling rates employed which lie in the range of 0.26° C./min and 1.3° C./min.
[0022] A more rapid cooling is undesirable because it destroys the aerosol and would have a disadvantageous effect on the cooling process and on the quality of the dough piece.
BRIEF DESCRIPTION OF THE DRAWING
[0023] The invention is explained in greater detail below with reference to the accompanying drawing. The FIGURE shows the curve of the core temperature for different bread dough pieces in reaction to the room temperature.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In the FIGURE, the line A represents the curve of the core temperature in a rye bread dough piece, line B the curve of the core temperature in a piece of whole-grain dough, the curve of the core temperature in a piece of pumpkin seed bread dough in the pan and D the curve of the core temperature in an additional piece of rye bread dough in the pan. The curve of the room temperature is indicated by the broken line.
[0025] For the production of a dough piece, the conventional ingredients and baking agents, a soaker and dry sourdough are prepared according to specified dough parameters to form a dough. After the dough has rested, the dough is conducted by means of a bowl tipper to the weighing machine. The dough pieces are weighed, shaped, allowed to fall into a coating or dusting mixture if necessary and placed on a baking sheet with or without parchment paper. The dough pieces are then moved on oven racks into a climate-controlled room. There they are first fermented for a specified period of time at a temperature of 15° C. (not shown in the FIGURE). The relative humidity in the climate-controlled room is thereby set to 100% by using an ultrasound atomizer to generate an aerosol of previously purified water in droplet form, whereby the droplets have a diameter of 10 μm or less. Measures which are themselves described in the prior art are employed during the entire process to ensure a constant and controllable circulation of the air at different speeds in the room. Contact with the aerosol droplets promotes the activity of both the yeast and the enzymes, as a result of which lower fermentation temperatures in the range of approximately 15° C. to 20° C. are possible. These lower fermentation temperatures allow the flour ingredients of the dough piece to swell, in particular if the fermentation is continued for a longer period, as a result of which aroma and flavors develop. It has been shown that with this method, the shelf life and stability of the dough piece are improved, which contributes to preserving quality during cooling, freezing and thawing.
[0026] Then the dough piece is cooled in a first cooling phase to −4° C. over a period of 15 minutes. This temperature lies above the specific freezing point of the dough piece which is assumed to be −7° C. for each point in the dough piece. First there is a superficial cooling of the dough, followed by a cooling of the core temperature. That is followed by a 15-minute plateau phase at −4° C., during which the relative humidity is adjusted as necessary and the aerosol is regenerated. Then the dough piece is cooled for an additional 15 minutes to approximately −10° C., at which point the cooling equipment is turned off. The goal is to stop the activity of the yeast, which occurs at approximately +6° C. Otherwise there is a risk that the yeast in the core of the dough piece will continue to ferment, which leads to cracks in the surface.
[0027] A rapid cooling is disadvantageous in the method claimed by the invention because it destroys the aerosol. If necessary, in addition to the above mentioned plateau phase, additional phases with a constant temperature can be added for the regeneration of the aerosol.
[0028] During the adjustment of the aerosol, the tolerance until the equipment is turned back on is approximately 1.5° C., which explains the rise in the room temperature until the end of the cooling time, which is approximately 1 h.
[0029] Only when the core temperature of the dough piece has reached +6° C., i.e. 65 to 95 minutes after the beginning of the cooling, depending on the type of dough piece, the cooling equipment can be turned on full. After the room temperature has been lowered further, it is maintained between −20° C. and −25° C. until the core temperature reaches −7° C. That is the case after approximately 2 hours and 30 minutes for a rye bread dough piece, approximately 2 hours and 45 minutes for a whole-grain bread dough piece and a pumpkin seed bread dough piece in a pan and approximately 3 hours for the additional rye bread dough piece in a pan. Because with the dough pieces that are in a pan, the moisture can act over only a small surface area, it takes somewhat longer to reach the desired core temperature in those cases. The rye bread dough piece is also relatively heavy, as a result of which a longer treatment time is observed.
[0030] The dough pieces prepared in this manner can then be deep-frozen and packaged, e.g. in polyethylene bags, and stored centrally in a freezer. The frozen bread doughs are then delivered via an appropriate logistics system to bakeries, where they are initially stored locally in the deep freezer. The dough pieces can then be removed from the freezer as needed, thawed according to specified parameters and baked according to the appropriate baking procedure. In this manner, fresh breads are constantly available in the bakeries as required.
[0031] Using the method claimed by the invention, a spatial separation is achieved between the location in which the dough pieces are produced and the site in which they are baked, which results in perceptible quality advantages. The method claimed by the invention also makes it possible to ship a reduced basic selection in the form of frozen dough pieces and to transform them locally into a large, attractive selection of baked goods. Baked goods are no longer baked centrally and need no longer be delivered fresh-baked daily, an operation which is both expensive and time consuming.
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Method for the production of dough pieces suitable for long-term storage in which the dough pieces are placed in a climate-controlled room, a relatively humidity of 100% is established, whereby water is atomized at a droplet size <10 μm; and the temperature of the room is lowered and the lowered temperature is maintained until the core temperature of the dough piece is below the specific freezing point of the dough piece.
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BACKGROUND OF THE INVENTION
The present invention relates to cylinder locks, and particularly to a device and method for its use for determining the required profile for a key for such a lock, without first unlocking the lock.
Cylinder locks are of several types such as those including pin tumblers and those including wafer tumblers which must be pushed into the proper positions by inserting a key into a keyhole in the cylinder of the lock in order for the cylinder of the lock to be turned relative to the outer casing. When the proper key is used the pin tumblers or wafer tumblers are moved to a position in which each tumbler is located within the volume defined generally by the outer surface of the cylinder of the lock. If the profile of the key is not correct, however, one or more of the tumblers extends from the inner cylinder into an appropriate groove in the surrounding casing, preventing the cylinder from being turned relative to the casing.
When the key from a lock has been lost a new key can be made by disassembling the lock to determine the proper profile, but this is often a very expensive procedure, because of the amount of time required to remove the lock from, for example, a door of an automobile. It is therefore desired to construct a new key without having to disassemble the lock.
As shown in Rubens U.S. Pat. No. 3,087,050 it is known that cylinder locks having wafer tumblers can be decoded to permit a new key to be cut, without unlocking the lock, by visually observing the positions of the individual wafers with the aid of a lamp and a probe which is used to hold some of the tumbler wafers out of the line of sight while observing others. This method of decoding a lock requires accurate estimation of the position of each tumbler within the lock, which may be difficult, because of the small differences in locations of tumbler positions, or because of reflections of light within the lock.
Hansen U.S. Pat. No. 1,991,151 shows a device used for decoding cylinder locks, but the device shown by Hansen appears to be somewhat complex and to be somewhat slow to use. Other devices, such as those shown in Harwell U.S. Pat. Nos. 2,720,032 and 2,791,840, and in Abrams U.S. Pat. No. 2,087,423, Tampke U.S. Pat. No. 2,727,312, and Nail U.S. Pat. No. 4,185,482 require that a lock first be opened before those devices can be used to determine the correct profile of a key for the lock. That is, the tumblers must all be moved to the position in which the break line of each tumbler corresponds with the surface between the inner and outer cylinders of the lock.
Johnstone U.S. Pat. No. 2,338,768, and Jarm U.S. Pat. No. 4,186,577 show devices which aid in picking cylinder locks. Johnstone discloses a set of partial keys by which a lock can be opened by systematically trying different parts along a key shank to bring each tumbler into a position coinciding with the break line between the cylinder and the surrounding casing. European patent application 82303966.4 discloses a device for picking a lock, in which a device is used to raise all of the tumblers to a non-interfering position to permit insertion into the keyway of a device which can be used to make an impression of the tumblers as they are allowed to move into an unlocked position.
Easley U.S. Pat. No. 4,517,746 discloses a lock decoding device including a probe including stiff wires which are rotatable within the probe to determine the positions and types of individual wafers of a certain type of cylinder lock without opening the lock. What is needed, however, is a simpler device, for use with wafer-type cylinder locks, to determine the proper profile for a key for such a lock without first having to pick the lock.
Ordinarily, the wafers of a wafer-type cylinder lock are interchangeable to make the lock use a different key. Each wafer is cut to one of several different sets of dimensions corresponding to a notch of a particular depth, to be located at a point along the shank of a key for such a lock which corresponds with the position in which that particular wafer tumbler is located within the cylinder of the lock. Any one of two to five or more different wafers might be in any particular wafer position of the cylinder, and what is needed is a device to determine which wafer is in each position of the cylinder of the lock, without first having to pick and open the lock. In wafer-type cylinder locks of the type for which a preferred embodiment of the present invention is intended, a hole is provided centrally in each wafer, permitting the wafer to move within the cylinder when a key is inserted into the keyhole. The position of the hole relative to the ends of the wafer determines the required depth of the notch on the working surface of a key, for each wafer position of the cylinder of the lock.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings of the prior art and provides a device and a method for its use for decoding a cylinder lock; that is, for determining the profile required for a key for a wafer-type cylinder lock, without having to unlock or disassemble the lock. In a preferred embodiment, a lock decoding device according to the present invention includes an elongate main body including a shank portion which fits within the keyway of the lock while the lock remains locked. The shank of the lock decoding device includes a notch which is deep enough to receive one wafer of the lock and allows that wafer to move to the position which it normally occupies when the lock is locked. The shank of the lock decoding device of the invention holds any wafers located closer to the face of the lock in a raised position, keeping them out of the way of a feeler which is inserted into the keyway alongside the shank of the lock decoding device.
The feeler used as a part of the lock decoding device of the present invention slides along the shank of the lock decoding device in a groove provided, until a front end of the feeler comes into contact with the key-engaging inner surface of the hole of the wafer located within the notch defined in the shank portion. Cooperating markings are provided on the feeler and on the head of the lock decoding device, to indicate the position of the front end of the feeler with respect to the notch in the shank.
The front end of the feeler may be inclined, or it may include steps corresponding to the different possible cut depths of a key for the lock, so that discrete positions of the feeler will be provided to indicate the proper cut for the respective tumbler position of a key.
It is, therefore, a principal object of the present invention to provide an improved and simplified device for decoding wafer-type cylinder locks to enable a locksmith to manufacture a key for a lock without having to open the lock.
It is another important object of the present invention to provide a device for accurately measuring the locations of the several tumblers of a cylinder lock while it remains locked.
It is a principal feature of the lock decoding device of the present invention that it includes a shank portion which holds other tumblers out of the way of a feeler used to determine the proper cut dimension for each tumbler of the lock, in turn, while the lock remains in a locked condition.
It is another important feature of the lock decoding device of the present invention that it includes a handle and a feeler which have markings which provide a visual indication of the position of the front end of the feeler relative to a tumbler located within a notch defined in the shank portion.
A further important feature of the lock decoding device of the present invention is the provision of indicia on the shank portion of the device to indicate which of the several tumblers is located within the notch provided on the shank portion of the device.
An important advantage of the lock decoding device of the present invention is that it does not require that the lock be opened in order for it to be decoded.
Another advantage of the lock decoding device of the present invention is that it is more sturdily constructed than previously known lock decoding devices for cylinder locks.
A further advantage of the present invention is that it provides a method which is simpler than the previously known methods for determining the proper profile for a key for a cylinder lock.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a lock decoding device according to the present invention, together with a cylinder lock of a type with which the lock decoding device of the present invention may be used.
FIGS. 2, 3, and 4 show front views of wafers of a type included as tumblers in the lock shown in FIG. 1.
FIG. 5 is a sectional side view of the lock shown in FIG. 1, taken along line 5--5, and showing the lock decoding device of the present invention in use.
FIG. 6 is a sectional view of the lock shown in FIG. 1 taken along the line 6--6 of FIG. 5.
FIG. 7 is a sectional view of the lock shown in FIG. 1, taken along line 7--7 of FIG. 5.
FIG. 8 is a view similar to that of FIG. 5, showing a lock decoding device which is an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, in FIG. 1 a lock decoding device 10 is shown together with a cylinder lock 12. A dog 13 is attached to the lock 12 by a screw 15 and retains the cylinder 56 within the outer casing 62 of the lock. As shown in FIG. 5, a nut 17 holds the lock 12 in position, while the dog 13 is rotatable by the cylinder 56 when the lock is unlocked by the properly profiled key extending through the keyhole 19 into the keyway extending axially within the cylinder 56.
The lock decoding device 10 includes a main body 14 is similar to a key blank for the cylinder lock 12, including a handle 16, similar to the head of a key, and a shank 18. The shank 18 includes a sloped nose surface 20 and a notch 22 spaced a short distance away from the nose surface 20 along an upper margin 24 of an upper portion 26 of the shank 18. The upper portion 26 and upper margin 24 are narrower than the corresponding portions of an ordinary key blank, and a medial surface 28 is wider than the corresponding surface of a key for the lock 12. A groove 30 extends across the handle 16, aligned with the upper portion 26 and medial surface 28 as a guide for a feeler 32. The thickness 34 of the upper portion 26, and the thickness 36 of the feeler 32 are both small enough so that the total of the thicknesses 34 and 36 is small enough to fit within the keyhole of the cylinder lock 12.
It will be appreciated that the medial surface 28, for some locks, may be on the opposite side of the upper portion 26, depending upon the shape of the keyhole of the particular lock concerned. It will also be appreciated that the upper portion 26 corresponds to that portion of a key for a particular cylinder lock which is ordinarily cut or ground to the necessary profile to hold the tumblers in the correct position for opening the lock. Thus, the upper portion 26 may, in fact, be located otherwise than upward, depending upon the orientation of the lock 12.
Referring now also to FIGS. 2-7, the lock 12 is a typical wafer-type cylinder lock including a set of five wafer tumblers such as the wafers 38, 40, and 42 shown in FIGS. 2, 3, and 4.
As may be seen in FIG. 2, the wafer 38 defines an opening 44 a distance 46 away from its upper end, while the wafer 40 shown in FIG. 3 defines an opening 48 establishing a distance 50, greater than the distance 46, from the upper end of the wafer 40. Similarly, the wafer 42, shown in FIG. 4, defines an opening 52 located a distance 54 from the upper end of the wafer 42. The distance 54 is greater than the distance 50.
In a key cut to operate a lock such as the lock 12, for a position in which a wafer 38 is present, a notch of a particular depth, which may be referred to as a number one cut, is necessary to raise the wafer 38 to a position in which its ends are aligned with the surface of the inner cylinder 56 of the lock. Should a key be inserted into the lock 12 so that any notch other than a number one cut is located within the opening 44, the wafer 38 would extend into one of the grooves 58 and 60 defined by the outer case 62 of the lock 12, within which the cylinder 56 is located.
For a wafer 40, a cut or notch of a greater depth is needed in the position of a key where a wafer 40 is located, because of the greater distance 50. Because of the yet greater distance 54 between the opening 52 and the upper end of the wafer 42, yet a deeper cut, referred to herein as a number three cut, is required in a key in the position corresponding to the position of a wafer 42 in the lock 12.
Each wafer is located in a respective position in the lock 12 commonly referred to by numbering serially beginning nearest the face 74 of the cylinder 56 of the lock, as may be seen by referring to FIG. 5. Because the wafers 38, 40, and 42 are identical and interchangeable, except for the location of the openings 44, 48 and 52, and the corresponding distances 46, 50, and 54, the bottom end 64 of each wafer is located within the groove 60 of the casing 62, preventing the cylinder 56 from turning relative to the casing 62, unless a key is in the lock. Because each wafer must move the same distance from a locked position to an unlocked position within the cylinder 56, however, the different distances 46, 50, and 54 result in the upper interior surface 66 of the opening 44, the upper interior surface 68 of the opening 48, and the upper interior surface 70 of the opening 52 being at different heights when the respective wafers 38, 40, and 42 are in their locking positions. Thus, to determine what depth of cut is required at each wafer position of a key to open a lock, it is sufficient to know the position of the upper interior surface of the hole in each wafer when that wafer is in a locking position, with its bottom end 64 located within the groove 60.
In accordance with the present invention, the shank 18 of the lock decoding device 10 is provided with indicia 72 to indicate, by reference with the face 74 of the cylinder 56, which of the several wafers within the cylinder 56 is aligned with the notch 22 defined in the upper portion 26 of the shank 18.
Because the nose surface 20 is sloped with an inclination similar to that of the front of a key for the lock 12, as the shank 18 is inserted into the lock 12, each wafer is pushed upward so that its upper end extends upwardly into the groove 58 by contact of the nose surface 20 with the upper interior surface 66, 68, or 70 of the wafer. When only the shank 18 is inserted into the lock, the wafer in position one, closest to the face 74 of the cylinder 56 is free to drop into the notch 22. The notch 22 is deep enough to provide ample clearance for the wafer requiring the deepest cut, in this case a wafer 43, and the medial surface 28 is similarly located lower than the height of the upper interior surface of the hole in such a wafer. Insertion of the feeler 32, or a similar device having an inclined forward surface similar to the inclined forward surface 76 of the feeler 32, will therefore raise any wafer from the notch 22 and permit the shank to be inserted further into the cylinder 56. The upper margin 24 of the shank 18 is chamfered on either side of the notch 22, where the sides of the notch 22 meet the upper margin 24, when the feeler 32 is resting along the medial surface 28 and within the groove 30. This enables each of the wafers to ride up onto the upper margin 24 as the shank 18 is inserted into the cylinder 56 beyond the number one wafer position although the upper margin 78 of the feeler 32 is not quite as high as the upper margin 24 above the medial surface 28, as will be clear from FIGS. 5 and 6.
As shown in FIG. 5, the shank 18 has been inserted until the notch 22 is aligned with wafer position five of the cylinder 56. The wafer 40 of position five of the lock 12 is located in the notch 22 and has been urged into its normal locking position by its associated spring. As a result, the bottom end 64 of the wafer 40 located in position five of the cylinder 56 is within the groove 60 at the bottom of the casing 62, as shown in FIGS. 5 and 7, and the upper interior surfaces of the openings of the wafers in positions closer to the face 74 than any wafer located within the notch 22 will not cause friction against the upper margin 78 of the feeler 32.
It will be noted that indicia 80 are provided on the handle 16 of the main body 14, and that an indicator mark 82 is provided on the face of the feeler 32. When the feeler 32 is moved along the shank 18 until its inclined forward surface 76 encounters the upper interior surface 66, 68 or 70 of a wafer located in the notch 22, the indicator mark 82 will be aligned with a particular mark of the indicia 80. For example, the indicator mark 82 is aligned with the mark labeled "2" of the indicia 80, in FIG. 5, where the inclined upper surface 76 is in contact with the upper interior surface 68 of the wafer 40 which is located within the notch 22. By referring to the indicia 72, it will be noted that the mark indicating the fifth wafer position is aligned with the face 74 of the cylinder 56 so that the lock decoding device 10 provides an indication that the wafer in position five requires a number two cut in the number five position of a key for that lock 12.
In order to decode a lock and manufacture a key to fit a lock which is locked, without having to pick the lock in order to determine the required key profile, then, it is necessary only to use the lock decoding device 10 of the present invention made for the particular type of lock. The type of lock which can be determined by reference to an available directory, entered by the application, such as a model and year of automobile. The relative location of the feeler 32 with respect to the main body 14, as shown by the indicia 80 and the mark 82, indicates the proper cut for a key for the wafer located in each of the wafer positions in turn, as explained above in detail with respect to the wafer in position five. Once the proper cut has been determined for each of the wafers, the feeler 32 is used to raise the final wafer from its position within the notch 22, and the shank 18 and feeler 32 are removed simultaneously from the lock.
Because the locks built by different manufacturers and used in different applications have different dimensions and may have different numbers of possible cuts for each wafer, it is easiest to refer to data provided by the manufacturer of the lock, in preparing a lock decoding device 10 according to the present invention, so that the indicia 80 will be accurate.
Once the proper cut has been determined for each wafer position of the cylinder lock 12, by use of the lock decoding device 10, the locksmith can refer to tables provided by lock manufacturers to select the proper key blank and cut the key to the proper profile according to the information provided by the manufacturer of the lock.
Because the wafers of a lock may become worn after extensive use, the indications provided by the indicia 80 and a feeler 32 for a particular lock may not be precise, as the slope of the inclined forward surface 76 of the feeler 32 must not be so shallow as to result in contact with the surface 76 against the upper interior surface of a wafer spaced further from the face 74 of the cylinder 56 than the wafer located in the notch 22. To avoid possible ambiguity resulting from a worn lock, an alternative to the inclined forward surface 76 of the feeler 32 is provided in the feeler 90 which has three parallel horizontal upper surfaces 92, 94, 96, corresponding to three different cut depths, as shown in FIG. 8. Vertical surfaces 100 interconnect the horizontal surfaces 92, 94, and 96 and act as positive stops to prevent the feeler 90 from proceeding into the central opening in a particular wafer beyond a position determined by the location of the opening within the wafer, when the wafer is located within the notch 22 of the shank 18. When using the feeler 90, it will be necessary to use a device, such as the feeler 32, which has an inclined upper front surface, such as the inclined forward surface 76 of the feeler 32, to raise each wafer clear from the notch 22 in order to move the shank 18 to a different wafer position within the cylinder 56 of the lock 12.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
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A device for decoding a cylinder lock of the wafer type includes a main portion having a shank similar to an uncut blank for a key for a particular lock and a thin feeler which slides along one side of the portion resembling a key blank. A notch is defined in the portion resembling a key blank, to receive a tumbler of the lock in a normal locking position for that tumbler while the feeler is placed into contact with the tumbler. Indicia are provided to indicate the position of the feeler with respect to the notch, in terms of nominal cut depths to which corresponding portions of a key must be cut to produce a key which will operate the lock. In one embodiment the feeler includes a sloping forward face which contacts a tumbler. In another embodiment of the invention the feeler includes a series of steps, each step corresponding to a particular nominal depth of cut for a position of a key to fit that tumbler of the lock into which the feeler is able to fit.
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TECHNICAL FIELD
This invention relates to a method and apparatus for metering flow in closed conduits that surcharge and more particularly to a method and apparatus for collecting and manipulating pressure data and converting it to flow data.
BACKGROUND
Engineers and scientists are frequently charged with the task of metering liquid flows in closed conduits that surcharge. For example, sanitary sewers that carry wastewater from areas that experience severe infiltration/inflow during wet weather typically operate under surcharged conditions during rainfall events. Similarly, culverts under roadways and storm sewers often operate as partially full open channels during dry weather but operate as full pipes during wet weather.
Applicant has previously disclosed a novel meter capable of metering flows in pipes that surcharge in U.S. Pat. Nos. 4,799,388 and 4,896,542. The meter is also described in a report entitled: "The Flumeter™: A New Tool for Wastewater Management" prepared for the U.S. Department of Energy Energy-Related Inventions Program by Yellowstone Environmental Science, Inc., Bozeman, Montana, May 1988.
The inventions disclosed in the above referenced documents rely on three conventional bubbler systems to transmit pressures produced by the primary element, a combination Venturi flume/Venturi tube of novel design, to two differential pressure sensing means in the secondary element or instrument. Alternatively, three piezoelectric pressure transducers may be used. With this option, electrical signals characterizing the pressures are transmitted to the secondary element.
Subsequent research has revealed that the disclosed pressure sensing methods have certain limitations. The three bubbler system has a higher power requirement than is desired for a portable flow meter. Furthermore, rapid increases in flow rates can cause momentary inaccuracies in pressure readings. The use of three submerged piezoelectric pressure transducers can also introduce inaccuracies because of the large range over which they must operate.
NATURE OF THE INVENTION
The present invention provides a method and apparatus for measuring flow in a closed conduit under both full and less than full conditions. The method and apparatus incorporate a tubular Venturi metering device. The cross section of the throat of the device is configured relative to the upstream section of the meter so that the throat will fill with liquid substantially simultaneously with the upstream section's filling with liquid. The method for designing the device so that this occurs is disclosed in the above-referenced patents and report.
The present method and apparatus incorporate an improved pressure transmitting and sensing means, a data logger/controller and a data converter. The pressure transmitting and sensing means is designed to overcome the limitations of the originally proposed means of transmitting and sensing pressures. Two embodiments are envisioned. One involves using submersible sensors to measure invert liquid pressures and a single bubbler system to transmit the throat (reference) pressure to the ends of the sensor vents (in the instrument case), thus allowing differential pressures to be measured. The second design involves transmitting pressures from sensing diaphragms via liquid-filled capillaries to both the pressure and reference ports of each of two (submersible) pressure sensors. This design would eliminate the bubbler mechanism. The data logger/controller is a conventional element programmed to accomplish its functions. The data converter includes a computer program needed to convert pressure data into flow rate data.
It is an object of the invention to provide an improved means of transmitting and sensing pressures produced by Applicant's tubular Venturi metering device. It is a further object of this invention to provide a computer program to operate a data logger/controller. Another object of the invention is to provide a computer program to convert the collected pressure data into flow rate data. Further objects and advantages of the invention will become apparent from a consideration of the drawings and ensuing description of it.
BRIEF DESCRIPTION OF THE DRAWINGS
These features will be better understood by reference to the accompanying drawings which illustrate presently preferred embodiments of the invention.
In the drawings:
FIG. 1 is a schematic drawing of a first preferred embodiment of the pressure transmitting and sensing subassembly.
FIG. 2 is a schematic drawing of a second preferred embodiment of the pressure transmitting and sensing subassembly.
FIG. 3 is a block diagram of a preferred method of operation of the logger/controller element of the invention.
FIGS. 4a and 4b are a block diagram of a preferred method of operation of the data converter.
FIG. 5 presents calibration curves for the meter.
FIG. 6 presents correction factor curves for submerged operation of the meter.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a schematic diagram of a preferred embodiment of the pressure transmitting and sensing subassembly or means is presented. Means of transmitting air or fluid pressure, (e.g. tubing) are illustrated as solid lines. Means of transmitting electrical signals are illustrated as dashed lines. This embodiment and the embodiment shown in FIG. 2 are capable of metering forward and reverse flows in closed conduits that surcharge. They are also capable of metering full pipe flow and both free and submerged open channel flow. An example of a closed conduit that typically operates in these modes is a sanitary sewer that carries excessive infiltration and inflow.
It is noted that the embodiments of the primary element illustrated herein comprise a bottom and top sill or constriction. The patents and reports referenced above illustrate how the invention can be implemented with only side constrictions, provided that the top of the throat is flat.
Tubular Venturi metering device 1 having longitudinal axis 5 is installed in a closed conduit 3 to produce pressures at various locations in the device that are used to determine flow rate. The means by which this is accomplished is disclosed in the above-referenced patents. Differential pressure transducer or sensor 2 is attached to the entrance section 4 of the device 1 and may be a submersible pressure transducer. Sensor 2 produces an electrical signal that is transmitted to data logger/controller 6 via wires 8. Sensor 2 is referenced to a reference pressure via vent tube 10. Wires 8 and tube 10 may be incorporated into the lead used to supply power to sensor 2.
Differential pressure transducer or sensor 12 is attached to the exit section 14 of device 1 and may be a submersible pressure transducer. Sensor 12 also produces an electrical signal that is transmitted to data logger/controller 6 via wires 16. Sensor 12 is referenced to a reference pressure via vent tube 18. Wires 16 and tube 18 may be incorporated into the lead used to supply power to sensor 12.
One end of bubbler tube 20 is attached to port 22 located at the top 23 of the throat section 24 of device 1. Air in bubbler tube 20 escapes from port 22 in the form of bubbles when throat section 24 of device 1 is filled with liquid 25. The ends of tubes 10 and 18 are attached to bubbler tube 20. In this way, the pressure in bubbler tube 20 is the reference pressure for sensors 2 and 12.
Bubbler tube 20 is pressurized by air pump 30 which may introduce air directly into bubbler tube 20. In a preferred embodiment, air pump 30 is used to pressurize air tank 32. Discharge of air from air tank 32 into bubbler tube 20 is controlled by on/off valve 34 and by needle valve 36. On/off valve 34 is used to initiate and terminate bubbler tube pressurization. Needle valve 36 is used to vary the rate of bubble release through port 22. In this embodiment, pressure switch 40 senses the pressure in air tank 32 relative to the pressure in bubbler tube 20 downstream from needle valve 36. Thus, the pressure in bubbler tube 20 serves as the reference pressure for pressure switch 40. Pressure switch 40 is used to activate air pump 30 via conductor 42. In this way, the pressure in air tank 32 is controlled at a set pressure (e.g., 3.5 pounds per square inch) above the reference pressure in bubbler tube 20.
Purge tube 44 provides a bypass around on/off valve 34 and needle valve 36. Purge valve 46 on purge tube 44 is used to control purging activity. When purge valve 46 is open, the contents of air tank 32 are discharged into bubbler tube 20 and leaves bubbler tube 20 via port 22. Thus, by opening of purge valve 46, any liquid or solid that has entered bubbler tube 20 or that has partially blocked port 22 can be purged from the system.
Differential pressure sensor 50 is connected to bubbler tube 20 and is referenced (vented) to ambient air pressure. Thus, sensor 50 senses the pressure in bubbler tube 20 relative to ambient air pressure. Sensor 50 produces an electrical signal that is transmitted to data logger/controller 6 via wires 52.
Also shown on FIG. 1 is a portable computer 51 comprising a central processing unit having memory 21. Data logger/controller 6 may be interrogated by computer 51 in which data conversion is accomplished.
An alternative embodiment of the device to that shown in FIG. 1 is appropriate for closed conduits that do not surcharge because the flow or conduit is choked or flooded out downstream from the metering location. One example of such a situation would be at the end of a storm drain that discharges into a river above the high water level. Another example would be at the end of the conduit that serves as a dam spillway wherein the discharge is a free jet. In this embodiment, no differential pressure transducer or sensor 12 is provided. The only differential pressure transducer or sensors required are upstream sensor 2 and throat top sensor 50. A downstream sensor is not required because neither reverse flow nor submerged operation (over the modular limit of the device) can occur.
A second preferred embodiment of the pressure transmitting and sensing subassembly or means is presented in schematic form in FIG. 2. Diaphragm 60 is attached to the entrance section 4 of tubular Venturi metering device 1, and, preferably, to the invert (bottom) of entrance section 4. Pressure imposed on diaphragm 60 is transmitted via capillary tube 62 to the pressure side of differential pressure sensor 64. Diaphragm 66 is attached to the top of throat section 24 of device 1. Pressure imposed on diaphragm 66 is transmitted via capillary tube 68 to the reference side of differential pressure sensor 64. Sensor 64 produces an electrical signal that is transmitted to data logger/controller 6 via wires 72. Wires 72 may be incorporated into the lead used to supply power to sensor 64.
Pressure imposed on diaphragm 60 is also transmitted via capillary tube 80 to the pressure side of pressure sensor 82. Pressure sensor 82 is referenced (via vent 84) to ambient air pressure. Sensor 82 produces an electrical signal that is transmitted to data logger/controller 70 via wires 86. Wires 86 and vent 84 may be incorporated into the lead used to supply power to sensor 82.
In the preferred embodiment, diaphragm 90 is attached to the exit section 14 of device 1, and, preferably, to the invert of exit section 14. Pressure imposed on diaphragm 90 is transmitted via capillary tube 92 to the pressure side of differential pressure sensor 94. Pressure imposed on diaphragm 66 is also transmitted via capillary tube 96 to the reference side of differential pressure sensor 94. Sensor 94 produces an electrical signal that is transmitted to data logger/controller 70 via wires 98. Wires 98 may be incorporated into the lead used to supply power to sensor 94.
In an alternative embodiment (shown as dotted lines on FIG. 2), capillary tube 80 is not provided. Instead, pressure imposed on diaphragm 66 is also transmitted via capillary tube 88 to the pressure side of pressure sensor 82, which operates as noted above.
Referring to FIG. 3, a block diagram is presented of a preferred method of operation of the logger/controller element of the invention. In one preferred method, pressure sensors 2, 12 and 50 are involved. Initially, at step 200, the logger/controller is "awakened", that is, switched from a low power consumption mode to an active mode. Awakening occurs at a preselected (preprogrammed) sampling frequency, e.g., every five minutes. At step 202, first, second and third differential pressure sensors 2, 12 and 50 are activated by energizing them with electricity. The output of sensors 2, 12 and 50 are allowed to settle and reach relatively consistent values during step 204. At step 206, the output of sensor 50 is sampled for about 10 seconds. During sampling, the sensor output values that occur during short periods (lasting about 3 microseconds) is placed in a temporary memory. These output values are averaged at step 208 to produce an average value. At step 210, the average value is compared to the value zero. If the average value is approximately zero (indicating that sensor 50 is sensing ambient air pressure), the next step is step 216. If not, at step 211, a check is made to determine the number of measurements which have been made since the previous high pressure purging of the bubbler tube. If a (predetermined) sufficient number of cycles have occurred, purge valve 46 is opened for a set time interval in step 212. If not, the next step is 213. At step 213, the controller sends a signal to valve 34 causing it to open. When valve 34 is open, bubbler tube 20 is pressurized. At step 214, the outputs of sensors 2, 12 and 50 are allowed to settle and reach a relatively consistent value. The date and time exhibited by the internal clock of the logger/controller is read at step 216. At step 218, the outputs of sensors 2, 12 and 50 are sampled and averaged over a preselected (preprogrammed) sampling period, e.g., for one minute. At step 220, if valve 34 is open, the controller sends a signal to valve 34 causing it to close. The sampled output values are averaged at step 222 to produce average values. At step 224, the average output values and the date/time value are placed in the long-term logger memory. At step 226, the sensors are switched off. At step 228, the logger/controller is "put to sleep," that is, it is switched from an active mode to a low power mode to conserve energy. At step 230, the data logger/controller is kept in sleep mode for a fixed (predetermined) time interval. At step 232, the program returns to step 200 to begin another measurement cycle.
In an alternative embodiment of the method of operation of the logger/controller element of the invention, pressure sensors 64, 82 and 94 are involved. The method is the same as the previously disclosed method except that these sensors are used instead of sensors 2, 12 and 50.
It will be apparent to those skilled in the art that the preferred method of operation of the logger/controller element is not the only possible such method. For example, in some situations, wherein energy conservation is not required, the unit need not be switched between an active mode and a low power mode. Furthermore, the order of the steps may be changed (e.g., when the date/time is read) or some steps may be deleted (e.g., eliminate the value averaging steps).
Referring to FIGS. 4a and 4b, a block diagram is presented of a preferred method of operation of the data converting element of the invention. In a preferred embodiment, data conversion is accomplished by means of a computer program resident in a portable (hand-held or lap top) computer. Alternatively, a program for data conversion may be resident in the central processing unit of the data logger/controller element. For the purposes of this disclosure, it is assumed that the program is resident in a water-tight portable computer that is used to interrogate the data logger/controller memory.
Initially, at step 400, the data converter reads the meter serial number and location. These data will have been input to the data logger/controller previously. At step 402, the data logger/controller is interrogated, that is, the following data value sets are read for each date/time:
Sensor 2 output value
Sensor 12 output value
Sensor 50 output value
It will be apparent that the data sets would consist of the values of sensors 64, 82 and 94 with the alternative embodiment described above. The example described below uses sensor 2, 12 and 50 output values. In any event, the stored output pressure values for each sensor are transferred from the memory of the data logger/controller to the memory of the data converter.
The remaining steps in the method are performed sequentially on each data set (each set of three values). At step 404, the direction of flow through the primary element is determined by comparing the values from sensor 2 (S2) and sensor 12 (S12). By this means, a determination is made of which of the first and second differential pressure sensors is upstream from the other. If S2 is greater than S12, the flow direction is forward, and the program advances to step 406. At step 406, S2 is compared to the pressure which occurs when the throat just fills with the liquid being metered (the throat depth value, TDV). If S2 is greater than the TDV, the flow condition is forward direction, full pipe, upper curve zone (FIG. 5, zone 501). The next step is 408, wherein flow rate Q1 is determined from function Fl, with S2 as the independent variable and Q1 as the dependent variable.
The functions F1, F2, F3, F4, F5, F6, and F7 discussed herein may consist of either algorithms or look-up tables. For the purposes of this disclosure, the means of relating pressure sensor output values to flow rates comprise the calibration curves shown in FIG. 5 and the correction curves shown in FIG. 6. A 10-inch (diameter) meter size was used to produce the data upon which the curves were based. The curves in FIG. 5 comprise a first lower zone 502, a second lower zone 503 and an upper zone 501. In the embodiment disclosed herein, the same curves are used for forward and reverse flow. In FIG. 5, the open data points represent data values corresponding to open channel free flow, i.e., flows occurring when the throat of the primary element is not filled, and the upstream flow depth is not affected by submergence (i.e., downstream tailwater levels do not exceed the modular limit of the device). The solid data points represent values corresponding to full pipe flow, i.e., flows occurring when the throat of the primary element is filled. To produce FIG. 5, sensor outputs were obtained at three different pipe slopes (the slope, in percent, of the axis of the pipe with respect to the horizontal). In FIG. 5, data collected at slopes of 0.24%, 1%, and 2% are represented by data point squares, triangles, and circles, respectively.
Data shown on FIG. 6 were collected at various flow rates, with each flow rate defined as a certain proportion of the full gravity (open channel) flow capacity (Q) of the primary element. The circle, triangle and plus sign data points correspond to flow rates of 0.25Q, 0.5Q, and 0.75Q, respectively.
The next step is 420, where the computed flow rate is plotted versus the time of data collection, and written into memory. The program then advances to step 422, wherein the next set of data values are read from memory. The program then returns to step 404, and a new flow rate is calculated from the new data values.
If S2 is less than the TDV at step 406, the next step is 410, where the value of the throat sensor 50 (S50) is compared to zero. If S50 is approximately equal to zero (plus or minus 0.1 pounds per square inch), the flow condition is forward direction, open channel flow. The next step is 414, wherein preliminary flow rate Q3 is computed from function F3, with S2 as the independent variable and Q3 as the dependent variable. The next step is 416, wherein the ratio S12/S2 is compared to the maximum submergence (i.e., the modular limit, ML). If S12/S2 is less than the ML, the flow condition is forward direction, open channel free flow (FIG. 5, zone 502), and the program advances to step 420.
If the ratio S12/S2 is greater than the ML at step 416, the flow condition is forward direction, open channel submerged flow. The next step is 418, where flow rate Q4 is computed from function F4. F4 is an iterative process that uses both the calibration curves and the correction curves. An initially corrected flow rate Q4 is calculated by multiplying Q3 by a correction factor derived from the correction curve on FIG. 6. This correction factor is a function of both Q3 and the ratio S2/S12. The initially computed value of Q4 is used to determine a new correction factor, and a new value for Q4 is calculated by multiplying the old value of Q4 by the new correction factor. The process is repeated until consecutively calculated Q4 values converge and differ by less than one percent. The program then advances to step 420.
At step 410, if S50 is not approximately equal to zero, the flow condition is forward direction, full pipe flow and the lower curve zone (FIG. 5, zone 503) is used. The next step is 412, wherein flow rate Q2 is computed from function F2, with the differential entrance to throat pressure value S2 as the independent variable, and Q2 as the dependent variable. The program then advances to step 420.
If S12 is greater than S2 at step 404, the flow direction is reverse, and the program advances to step 426, wherein S12 is compared to the TDV. If S12 is greater than the TDV, the flow condition is reverse direction, full pipe flow and upper curve zone (FIG. 5, zone 501) is used. The next step is 428, wherein flow rate Q5 is computed from function F5, with S12 as the independent variable and Q5 as the dependent variable. The program then advances to step 420.
If S12 is less than the TDV in step 426, the next step is 30, where S50 is compared to zero. If S50 is approximately equal to zero (plus or minus 0.1 pounds per square inch), the flow condition is reverse direction, open channel flow. The next step is 434, wherein the preliminary flow rate Q7 is computed from function F7, with S12 as the independent variable and Q7 as the dependent variable. The program advances to step 436, wherein the ratio S2/S12 is compared to the ML. If the ratio S2/S12 is less than the ML, the flow condition is reverse direction, open channel free flow, and the lower curve zone (FIG. 5, zone 503) is used. The program then advances to step 420.
If the ratio S2/S12 exceeds the ML in step 436, the flow condition is reverse direction, open channel submerged flow. The next step is 438, wherein flow rate Q8 is computed by means of iterative function, F8. In F8, an initially corrected value for Q8 is calculated by multiplying Q7 by a correction factor. This correction factor is a function of Q7 and the ratio S2/S12. The initial value of Q8 is used to determine a new value for the correction factor, and a new value of Q8 is calculated by multiplying the old value of Q8 by the new correction factor. This process is repeated until consecutively calculated values of Q8 converge to within one percent. The program then advances to step 420. When all the data sets have been converted to flow rates, the program stops at step 422.
The algorithms or look-up tables used in the flow rate calculations may be the same for both forward or reverse flow conditions with some meter designs. The modular limits for forward and reverse flow may also be the same. If the meter is installed in the entrance sewer of a sewer manhole and discharges into the unconfined (open) conduit in the manhole, different algorithms or look-up tables may be required for forward and reverse flow conditions. If reverse and/or submerged flow conditions would not occur, those steps may be eliminated from the program.
Many variations of the invention will occur to those skilled in the art. All such variations within the scope of the claims are intended to be within the scope and spirit of the invention.
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A method and apparatus for measuring flow in a closed conduit under both full and less than full conditions is disclosed. The method and apparatus incorporate a tubular Venturi metering device. The cross section of the throat of the device is configured relative to the upstream section of the meter so that the throat will fill with liquid substantially simultaneously with the upstream section's filling with liquid. The present method and apparatus incorporate an improved pressure transmitting and sensing means, a data logger/controller and a data converter. The pressure transmitting and sensing means is designed to overcome the limitations of prior art means of transmitting and sensing pressures. One embodiment involves using submersible sensors to measure invert liquid pressures and a single bubbler system to transmit the throat (reference) pressure to the ends of the sensor vents (in the instrument case), thus allowing differential pressures to be measured. A second design involves transmitting pressures from sensing diaphragms via liquid-filled capillaries to both the pressure and reference ports of each of two (submersible) pressure sensors. The data logger/controller is a conventional element programmed to accomplish its functions. The data converter includes a computer program needed to convert pressure data into flow rate data.
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RELATED APPLICATIONS
[0001] This application claims priority from provisional patent application serial number 60/526,128, filed Dec. 1, 2003.
TECHNICAL FIELD
[0002] The invention is in the field of compositions for treatment of keratinous surfaces such as skin (including lips), hair and nails.
BACKGROUND OF THE INVENTION
[0003] Cosmetics companies are on an eternal quest to provide cosmetics that provide an immediate as well as long term beauty benefit. For example, women typically use foundation makeup to cover skin imperfections and improve the appearance of facial skin, not thinking of foundation as a skin conditioning composition. The same is true for other color cosmetic products such as lipsticks, blushes, concealers, eyeshadows, and the like. Typically they are used by women to provide immediate beauty benefits, and are not considered by such users to be skin conditioning or anti-aging products. Products such as skin creams and lotions are often thought of as providing long term beauty benefit in that consistent use of such products over a longer time period will provide some benefit such as wrinkle reduction, improvement in skin tone, and so on, with respect to the keratinous surface to which they are applied. As the baby boomer population ages, a much larger percentage of women must contend with the effects of age on skin. Wrinkles, sags, age spots, and other effects of age become evident. Such consumers have a need for skin treatment and color products that provide both skin conditioning and anti-aging properties as well as the desired immediate beauty benefit.
[0004] It has been discovered that a certain hexapeptide provides excellent anti-aging properties and is compatible with a wide variety of the ingredients used in cosmetic products.
[0005] It is an object of the invention to provide skin conditioning and beautifying compositions containing anti-aging and skin conditioning hexapeptides.
[0006] It is a further object of the invention to provide color cosmetic compositions comprising hexapeptides.
[0007] It is a further object of the invention to provide cosmetic compositions comprising Acetyl Hexapeptide-3.
SUMMARY OF THE INVENTION
[0008] The invention is directed to a cosmetic composition comprising Acetyl Hexapeptide-3 in a cosmetically acceptable carrier.
[0009] The invention is further directed to a cosmetic composition for improving skin conditions associated with aging such as wrinkles, fine lines, laxity, mottled pigmentation, and sallowness comprising Acetyl Hexapeptide-3 in a cosmetically acceptable carrier.
[0010] The invention is further directed to a color cosmetic composition comprising Acetyl Hexapeptide-3 and at least one cosmetically acceptable pigment.
[0011] The invention is further directed to a water and oil emulsion color cosmetic composition comprising Acetyl Hexapeptide-3.
[0012] The invention is further directed to pigmented anhydrous cosmetic composition comprising Acetyl Hexapeptide-3.
DETAILED DESCRIPTION
[0013] The term “keratinous surfaces” means the surfaces of skin, hair and nails. The term “skin” when used herein is in the broad sense meaning the skin of the face, body, and neck as well as the lips.
[0014] The compositions of the invention may be anhydrous, or in the emulsion form. If the latter, the emulsions may be water-in-oil or oil-in-water. Suitable water and oil emulsions contain about 0.1-95%, preferably about 0.5-85%, more preferably about 5-85% by weight of the total composition of water and about 0. 1-99%, preferably about 1-90%, more preferably about 3-85% by weight of the total composition of oil.
[0000] I. The Hexapeptide
[0015] The hexapeptide used in the compositions of the invention has the INCI name Acetyl Hexapeptide-3, having the chemical name acetyl glutamyl-glutamyl-methyonyl-glutamyl-arginyl-arginylamide. The peptide may be purchased from Lipotec under the tradename Argireline® in either the powder or solution form. The powder form appears as a white to off-white powder comprising about 2.7 to 3.3% Glutamic acid, about 0.6 to 1.0% Methionine, and about 1.8 to 2.2% Arginine. The solution form is a transparent solution containing about 0.05% powder in water and about 0.5% preservative.
[0016] The compositions of the invention preferably contain from about 0.00001-25%, preferably about 0.00005-20%, more preferably about 0.001-18% by weight of the total composition of Acetyl Hexapeptide-3.
[0000] II. The Cosmetically Acceptable Carrier
[0017] The Acetyl Hexapeptide-3 may be incorporated into a variety of skin care compositions, including but not limited to gels, creams, lotions, sunscreens, and the like. In addition, the Acetyl Hexapetide-3 used in the compositions of the invention may be used in color cosmetic compositions such as foundation makeups, blushes, eyeshadows, mascaras, concealers, eyeliners, lip colors, nail colors, and so on.
[0018] Compositions that may be found in the emulsion form, for example, creams, lotions, sunscreens, foundation makeups, concealers, lipcolor, and the like, may be water-in-oil or oil-in-water emulsions. Preferably such emulsions comprise from about 0.1-95%, preferably about 0.5-85%, more preferably about 5-85% by weight of the total composition of water and about 0.1-99%, preferably about 1-90%, more preferably about 3-85% by weight of the total composition of oil. In addition to oil, the other ingredients that may be found in such compositions include surfactants, sunscreens, particulates, film forming polymers, humectants, thickeners, structuring agents, and so on.
[0019] Other compositions in accordance with the invention, for example, eyeshadows, blushes, some types of concealers, lipcolor, some types of lashcolor, may be found in the anhydrous form. Typically such compositions comprise an oily phase ranging from about 0.1-99%, preferably about 1-90%, more preferably about 3-85% by weight of the total composition, with particulates, pigments, and other ingredients as further identified below.
[0020] A. Oils
[0021] If present, suggested ranges for such oils in the compositions of the invention are about 0.1-90%, preferably 0.5-75%, more preferably 1-60% by weight of the total composition. The oils used may be volatile or nonvolatile, and are liquid at room temperature. The term “volatile” means that the oil has a measurable vapor pressure, or a vapor pressure of at least about 2 mm. of mercury at 20° C. The term “nonvolatile” means that the oil has a vapor pressure of less than about 2 mm. of mercury at 20° C.
[0022] 1. Volatile Oils
[0023] Suitable volatile oils generally have a viscosity of about 0.5 to 10 centipoise at 25° C. Suitable volatile oils include linear silicones, cyclic silicones, paraffinic hydrocarbons, or mixtures thereof.
[0024] Cyclic silicones (or cyclomethicones) are of the general formula:
where n=3-6.
[0025] Linear volatile silicones in accordance with the invention have the general formula:
(CH 3 ) 3 Si—O—[Si(CH 3 ) 2 —O] n —Si(CH 3 ) 3
where n=0-7, preferably 0-5.
[0026] Linear and cyclic volatile silicones are available from various commercial sources including Dow Corning Corporation and General Electric. The Dow Corning volatile silicones are sold under the tradenames Dow Corning 244, 245, 344, and 200 fluids. These fluids comprise octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, dodecamethylhexasiloxane, hexamethyldisiloxane, octamethyltrisiloxane, decamethyltetrasiloxane, dodecamethylpentasiloxane, and mixtures thereof. Examples of linear volatile silicones include octamethyltrisiloxane, decamethyltetrasiloxane, dodecamethylpentasiloxane, and the like.
[0027] Also suitable as the volatile oils are various straight or branched chain paraffinic hydrocarbons having 5 to 40 carbon atoms, more preferably 8-20 carbon atoms. Suitable hydrocarbons include pentane, hexane, heptane, decane, dodecane, tetradecane, tridecane, and C 8-20 isoparaffins as disclosed in U.S. Pat. Nos. 3,439,088 and 3,818,105, both of which are hereby incorporated by reference. Preferred volatile paraffinic hydrocarbons have a molecular weight of 70-225, preferably 160 to 190 and a boiling point range of 30 to 320, preferably 60-260 degrees C., and a viscosity of less than 10 cs. at 25 degrees C. Such paraffinic ydrocarbons are available from EXXON under the ISOPARS trademark, and from the Permethyl Corporation. Suitable C 12 isoparaffins are manufactured by Permethyl Corporation under the tradename Permethyl 99A. Another C 12 isoparaffin (isododecane) is distributed by Presperse under the tradename Permethyl 99A. Various C 16 isoparaffins commercially available, such as isohexadecane (having the tradename Permethyl R), are also suitable. Transfer resistant cosmetic sticks of the invention will generally comprise a mixture of volatile silicones and volatile paraffinic hydrocarbons.
[0028] 2. Non-Volatile Oils
[0029] A wide variety of nonvolatile oils are also suitable for use in the cosmetic compositions of the invention. The nonvolatile oils generally have a viscosity of greater than about 5 to 10 centipoise at 25° C., and may range in viscosity up to about 1,000,000 centipoise at 25° C.
[0030] (a). Esters
[0031] Suitable esters are mono-, di-, and triesters. The composition may comprise one or more esters selected from the group, or mixtures thereof.
[0032] (i). Monoesters
[0033] Monoesters are defined as esters formed by the reaction of a monocarboxylic acid having the formula R—COOH, wherein R is a straight or branched chain saturated or unsaturated alkyl having 2 to 30 carbon atoms, or phenyl; and an alcohol having the formula R-OH wherein R is a straight or branched chain saturated or unsaturated alkyl having 2-30 carbon atoms, or phenyl. Both the alcohol and the acid may be substituted with one or more hydroxyl groups. Either one or both of the acid or alcohol may be a “fatty” acid or alcohol, and may have from about 6 to 30 carbon atoms. Examples of monoester oils that may be used in the compositions of the invention include hexyldecyl benzoate, hexyl laurate, hexadecyl isostearate, hexydecyl laurate, hexyldecyl octanoate, hexyldecyl oleate, hexyldecyl palmitate, hexyldecyl stearate, hexyldodecyl salicylate, hexyl isostearate, butyl acetate, butyl isostearate, butyl oleate, butyl octyl oleate, cetyl palmitate, cetyl octanoate, cetyl laurate, cetyl lactate, isostearyl isononanoate, cetyl isononanoate, cetyl stearate, stearyl lactate, stearyl octanoate, stearyl heptanoate, stearyl stearate, and so on.
[0034] (ii). Diesters
[0035] Suitable diesters are the reaction product of a dicarboxylic acid and an aliphatic or aromatic alcohol. The dicarboxylic acid may contain from 2 to 30 carbon atoms, and may be in the straight or branched chain, saturated or unsaturated form. The dicarboxylic acid may be substituted with one or more hydroxyl groups. The aliphatic or aromatic alcohol may also contain 2 to 30 carbon atoms, and may be in the straight or branched chain, saturated, or unsaturated form. The aliphatic or aromatic alcohol may be substituted with one or more substituents such as hydroxyl. Preferably, one or more of the acid or alcohol is a fatty acid or alcohol, i.e. contains 14-22 carbon atoms. The dicarboxylic acid may also be an alpha hydroxy acid. Examples of diester oils that may be used in the compositions of the invention include diisostearyl malate, neopentyl glycol dioctanoate, dibutyl sebacate, di-C 12-13 alkyl malate, dicetearyl dimer dilinoleate, dicetyl adipate, diisocetyl adipate, diisononyl adipate, diisostearyl dimer dilinoleate, diisostearyl fumarate, diisostearyl malate, and so on.
[0036] (iii). Triesters
[0037] Suitable triesters comprise the reaction product of a tricarboxylic acid and an aliphatic or aromatic alcohol. As with the mono- and diesters mentioned above, the acid and alcohol contain 2 to 30 carbon atoms, and may be saturated or unsaturated, straight or branched chain, and may be substituted with one or more hydroxyl groups. Preferably, one or more of the acid or alcohol is a fatty acid or alcohol containing 14 to 22 carbon atoms. Examples of triesters include triarachidin, tributyl citrate, triisostearyl citrate, tri C12-13 alkyl citrate, tricaprylin, tricaprylyl citrate, tridecyl behenate, trioctyldodecyl citrate, tridecyl behenate, tridecyl cocoate, tridecyl isononanoate, and so on.
[0038] Esters suitable for use in the composition are further described on pages 1670-1676 of the C.T.F.A. Cosmetic Ingredient Dictionary and Handbook, Eighth Edition, 2000, which is hereby incorporated by reference in its entirety.
[0039] (b). Hydrocarbon Oils
[0040] It may be desirable to incorporate one or more non-volatile hydrocarbon oils into the composition. The term “nonvolatile” means that the oil has a vapor pressure of less than about 2 mm. of mercury at 20° C.
[0041] Suitable nonvolatile hydrocarbon oils include paraffinic hydrocarbons and olefins, preferably those having greater than 20 carbon atoms. Examples of such hydrocarbon oils include C 24-28 olefins, C 30-45 olefins, C 20-40 isoparaffins, hydrogenated polyisobutene, polyisobutene, mineral oil, pentahydrosqualene, squalene, squalane, and mixtures thereof.
[0042] (c). Lanolin Oil
[0043] Also suitable for use in the composition is lanolin oil or derivatives thereof containing hydroxyl, alkyl, or acetyl groups, such as hydroxylated lanolin, isobutylated lanolin oil, acetylated lanolin, acetylated lanolin alcohol, and so on.
[0044] (d). Glyceryl Esters of Fatty Acids
[0045] Naturally occurring glyceryl esters of fatty acids, or triglycerides, are also suitable for use in the compositions. Both vegetable and animal sources may be used. Examples of such oils include castor oil, lanolin oil, C 10 O 18 triglycerides, caprylic/capric/triglycerides, coconut oil, corn oil, cottonseed oil, linseed oil, mink oil, olive oil, palm oil, illipe butter, rapeseed oil, soybean oil, sunflower seed oil, walnut oil, and the like.
[0046] Also suitable are synthetic or semi-synthetic glyceryl esters, e.g. fatty acid mono-, di-, and triglycerides which are natural fats or oils that have been modified, for example, acetylated castor oil, or mono-, di- or triesters of polyols such as glyceryl stearate, diglyceryl diiosostearate, polyglyceryl-4 isostearate, polyglyceryl-6 ricinoleate, glyceryl dioleate, glyceryl diisotearate, glyceryl trioctanoate, diglyceryl distearate, glyceryl linoleate, glyceryl myristate, glyceryl isostearate, PEG castor oils, PEG glyceryl oleates, PEG glyceryl stearates, PEG glyceryl tallowates, and so on.
[0047] (e). Nonvolatile Silicones
[0048] Nonvolatile silicone oils, both water soluble and water insoluble, are also suitable for use in the composition. Such silicones preferably have a viscosity ranging from about 10 to 600,000 centistokes, preferably 20 to 100,000 centistokes at 25° C. Suitable water insoluble silicones include amine functional silicones such as amodimethicone; phenyl substituted silicones such as bisphenylhexamethicone, phenyl trimethicone, or polyphenylmethylsiloxane; dimethicone, alkyl substituted dimethicones, and mixtures thereof.
[0049] Such silicones have the following general formula:
wherein R and R′ are each independently C 1-30 alkyl, phenyl or aryl, trialkylsiloxy, and x and y are each independently 0-1,000,000 with the proviso that there is at least one of either x or y, and A is siloxy endcap unit. Preferred is where A is a methyl siloxy endcap unit, in particular trimethylsiloxy, and R and R′ are each independently a C 1-30 straight or branched chain alkyl, phenyl, or trimethylsiloxy, more preferably a C 1-22 alkyl, phenyl, or trimethylsiloxy, most preferably methyl, phenyl, or trimethylsiloxy, and resulting silicone is dimethicone, phenyl dimethicone, or phenyl trimethicone. Other examples include alkyl dimethicones such as cetyl dimethicone, and the like wherein at least one R is a fatty alkyl (C 12 , C 14 , C 16 , C 18 , or C 22 ), and the other R is methyl, and A is a trimethylsiloxy endcap unit.
[0050] (f). Fluorinated Oils
[0051] Various types of fluorinated oils may also be suitable for use in the compositions including but not limited to fluorinated silicones, fluorinated esters, or perfluropolyethers. Particularly suitable are fluorosilicones such as trimethylsilyl endcapped fluorosilicone oil, polytrifluoropropylmethylsiloxanes, and similar silicones such as those disclosed in U.S. Pat. No. 5,118,496 which is hereby incorporated by reference. Perfluoropolyethers include those disclosed in U.S. Pat. Nos. 5,183,589, 4,803,067, 5,183,588 all of which are hereby incorporated by reference, which are commercially available from Montefluos under the trademark Fomblin.
[0052] Fluoroguerbet esters are also suitable oils. The term “guerbet ester” means an ester which is formed by the reaction of a guerbet alcohol having the general formula:
and a fluoroalcohol having the following general formula:
CF 3 —(CF 2 ) n —CH 2 —CH 2 —OH
wherein n is from 3 to 40,
with a carboxylic acid having the general formula: R 3 COOH, or HOOC—R 3 —COOH wherein R 1 , R 2 , and R 3 are each independently a straight or branched chain alkyl.
[0057] The guerbet ester may be a fluoro-guerbet ester, which is formed by the reaction of a guerbet alcohol and carboxylic acid (as defined above), and a fluoroalcohol having the following general formula:
CF 3 —(CF 2 ) n —CH 2 —CH 2 —OH
wherein n is from 3 to 40.
[0058] Examples of suitable fluoro guerbet esters are set forth in U.S. Pat. No. 5,488,121which is hereby incorporated by reference. Suitable fluoro-guerbet esters are also set forth in U.S. Pat. No. 5,312,968 which is hereby incorporated by reference. One type of such an ester is fluorooctyldodecyl meadowfoamate, sold under the tradename Silube GME-F by Siltech, Norcross, Ga.
[0059] B. Surfactants
[0060] The compositions of the invention may comprise about 0.01-20%, preferably about 0.1-15%, more preferably about 0.5-10% by weight ofthe total composition of one or more surfactants. The surfactants present may be anionic, nonionic, cationic, zwitterionic, or amphoteric.
[0061] 1. Nonionic Surfactants
[0062] (a) Organic Nonionic Surfactants
[0063] The composition may comprise one or more nonionic organic surfactants. Suitable nonionic surfactants include alkoxylated alcohols, or ethers, formed by the reaction of an alcohol with an alkylene oxide, usually ethylene or propylene oxide. Preferably the alcohol is either a fatty alcohol having 6 to 30 carbon atoms. Examples of such ingredients include Steareth 2-100, which is formed by the reaction of stearyl alcohol and ethylene oxide and the number of ethylene oxide units ranges from 2 to 100; Beheneth 5-30, which is formed by the reaction of behenyl alcohol and ethylene oxide where the number of repeating ethylene oxide units is 5 to 30; Ceteareth 2-100, formed by the reaction of a mixture of cetyl and stearyl alcohol with ethylene oxide, where the number of repeating ethylene oxide units in the molecule is 2 to 100; Ceteth 1-45 which is formed by the reaction of cetyl alcohol and ethylene oxide, and the number of repeating ethylene oxide units is 1 to 45, and so on.
[0064] Other alkoxylated alcohols are formed by the reaction of fatty acids and mono-, di- or polyhydric alcohols with an alkylene oxide. For example, the reaction products of C 6-30 fatty carboxylic acids and polyhydric alcohols which are monosaccharides such as glucose, galactose, methyl glucose, and the like, with an alkoxylated alcohol.
[0065] Also suitable as nonionic surfactants are carboxylic acids, which are formed by the reaction of a carboxylic acid with an alkylene oxide or with a polymeric ether. The resulting products have the general formula:
where RCO is the carboxylic ester radical, X is hydrogen or lower alkyl, and n is the number of polymerized alkoxy groups. In the case of the diesters, the two RCO— groups do not need to be identical. Preferably, R is a C 6-30 straight or branched chain, saturated or unsaturated alkyl, and n is from 1-100.
[0066] Monomeric, homopolymeric, or block copolymeric ethers are also suitable as nonionic surfactants. Typically, such ethers are formed by the polymerization of monomeric alkylene oxides, generally ethylene or propylene oxide. Such polymeric ethers have the following general formula:
wherein R is H or lower alkyl and n is the number of repeating monomer units, and ranges from 1 to 500.
[0067] Other suitable nonionic surfactants include alkoxylated sorbitan and alkoxylated sorbitan derivatives. For example, alkoxylation, in particular ethoxylation of sorbitan provides polyalkoxylated sorbitan derivatives. Esterification of polyalkoxylated sorbitan provides sorbitan esters such as the polysorbates. Examples of such ingredients include Polysorbates 20-85, sorbitan oleate, sorbitan palmitate, sorbitan sesquiisostearate, sorbitan stearate, and so on.
[0068] (b). Silicone Surfactants
[0069] Also suitable as nonionic surfactants are various types of silicone surfactants, which are defined as silicone polymers that have at least one hydrophilic radical and at least one lipophilic radical. These silicone surfactants may be liquids or solids at room temperature. The silicone surfactant is, generally, a water-in-oil or oil-in-water type surfactant having a Hydrophile/Lipophile Balance (HLB) ranging from about 2 to 18. Preferably the silicone surfactant is a nonionic surfactant having an HLB ranging from about 2 to 12, preferably about 2 to 10, most preferably about 4 to 6. The HLB of a nonionic surfactant is the balance between the hydrophilic and lipophilic portions of the surfactant and is calculated according to the following formula:
HLB= 7+11.7×log M w /M o
where M w is the molecular weight of the hydrophilic group portion and M o is the molecular weight of the lipophilic group portion.
[0070] The term “silicone surfactant” means an organosiloxane polymer containing a polymeric backbone including repeating siloxy units that may have cyclic, linear or branched repeating units, e.g. di(lower)alkylsiloxy units, preferably dimethylsiloxy units. The hydrophilic portion of the organosiloxane is generally achieved by substitution onto the polymeric backbone of a radical that confers hydrophilic properties to a portion of the molecule. The hydrophilic radical may be substituted on a terminus of the polymeric organosiloxane, or on any one or more repeating units of the polymer. In general, the repeating dimethylsiloxy units of modified polydimethylsiloxane emulsifiers are lipophilic in nature due to the methyl groups, and confer lipophilicity to the molecule. In addition, longer chain alkyl radicals, hydroxy-polypropyleneoxy radicals, or other types of lipophilic radicals may be substituted onto the siloxy backbone to confer further lipophilicity and organocompatibility. If the lipophilic portion of the molecule is due in whole or part to a specific radical, this lipophilic radical may be substituted on a terminus of the organosilicone polymer, or on any one or more repeating units of the polymer. It should also be understood that the organosiloxane polymer in accordance with the invention should have at least one hydrophilic portion and one lipophilic portion.
[0071] The term “hydrophilic radical” means a radical that, when substituted onto the organosiloxane polymer backbone, confers hydrophilic properties to the substituted portion of the polymer. Examples of radicals that will confer hydrophilicity are hydroxy-polyethyleneoxy, hydroxyl, carboxylates, and mixtures thereof.
[0072] The term “lipophilic radical” means an organic radical that, when substituted onto the organosiloxane polymer backbone, confers lipophilic properties to the substituted portion of the polymer. Examples of organic radicals that will confer lipophilicity are C 1-40 straight or branched chain alkyl, fluoro, aryl, aryloxy, C 1-40 hydrocarbyl acyl, hydroxy-polypropyleneoxy, or mixtures thereof. The C 1-40 alkyl may be non-interrupted, or interrupted by one or more oxygen atoms, a benzene ring, amides, esters, or other functional groups.
[0073] The polymeric organosiloxane surfactant used in the invention may have any of the following general formulas:
M x Q y , or
M x T y , or
MD x D′ y D″ z M
wherein each M is independently a substituted or unsubstituted trimethylsiloxy endcap unit. If substituted, one or more of the hydrogens on the endcap methyl groups are substituted, or one or more methyl groups are substituted with a substituent that is a lipophilic radical, a hydrophilic radical, or mixtures thereof. T is a trifunctional siloxy unit having the empirical formula RSiO 1.5 or R′SiO 1.5 wherein R is methyl and R′ is a C 2-22 alkyl or phenyl, Q is a quadrifunctional siloxy unit having the empirical formula SiO 2 , and D, D′, D”, x, y, and z are as set forth below, with the proviso that the compound contains at least one hydrophilic radical and at least one lipophilic radical. Preferred is a linear silicone of the formula:
MD x D′ y D″ z M
wherein M=RRRSiO 0.5
D=RRSiO 1.0
D′=RR′SiO 1.0
D″=R′R′SiO 1.0
x, y, and z are each independently 0-1000,
where R is methyl or hydrogen, and R′ is a hydrophilic radical or a lipophilic radical, with the proviso that the compound contains at least one hydrophilic radical and at least one lipophilic radical.
[0075] Most preferred is wherein
M=trimethylsiloxy
D=Si[(CH 3 )][(CH 2 ) n CH 3 ]O 1.0 where n=0-40,
D′=Si[(CH 3 )][(CH 2 ) o —O—PE)]O 1.0 where PE is (—C 2 H 4 O) a (—C 3 H 6 O) b H, o=0-40,
a=1-100 and b=1-100, and
D″=Si(CH 3 ) 2 O 1.0
[0076] More specifically, suitable silicone surfactants have the formula:
wherein p is 0-40, and
PE is (—C 2 H 4 O) a (−C 3 H 6 O ) b —H
where x, y, z, a, and b are such that the maximum molecular weight of the polymer is approximately about 50,000.
[0078] Another type of silicone surfactant suitable for use in the compositions of the invention are emulsifiers sold by Union Carbide under the Silwet™ trademark. These surfactants are represented by the following generic formulas:
(Me 3 Si) y-2 [(OSiMe 2 ) x/y O—PE] y
wherein PE is
-(EO) m (PO) n R
where R=lower alkyl or hydrogen
Me=methyl EO is polyethyleneoxy PO is polypropyleneoxy m and n are each independently 1-5000 x and y are each independently 0-5000, and
wherein PE is
—CH 2 CH 2 CH 2 O(EO) m (PO) n Z
where Z=lower alkyl or hydrogen, and
Me, m, n, x, y, EO and PO are as described above, with the proviso that the molecule contains a lipophilic portion and a hydrophilic portion. Again, the lipophilic portion can be supplied by a sufficient number of methyl groups on the polymer.
[0086] As with both types of silicone surfactants, the hydrophilic radical can be substituted on the terminal portions of the silicone, or in other words in the alpha or omega positions or both.
[0087] Also suitable as nonionic silicone surfactants are hydroxy-substituted silicones such as dimethiconol, which is defined as a dimethyl silicone substituted with terminal hydroxy groups.
[0088] Examples of silicone surfactants are those sold by Dow Corning under the tradename Dow Corning 3225C Formulation Aid, Dow Corning 190 Surfactant, Dow Corning 193 Surfactant, Dow Corning Q2-5200, Abil WE97, and the like are also suitable. In addition, surfactants sold under the tradename Silwet by Union Carbide, and surfactants sold by Troy Corporation under the Troysol tradename, those sold by Taiwan Surfactant Co. under the tradename Ablusoft, those sold by Hoechst under the tradename Arkophob, are also suitable for use in the invention.
[0089] 2. Anionic Surfactants
[0090] If desired the composition may contain one or more anionic surfactants. If so, suggested ranges of anionic surfactant range from about 0.01-25%, preferably 0.5-20%, more preferably about 1-15% by weight of the total composition. Suitable anionic surfactants include alkyl and alkyl ether sulfates generally having the formula ROSO 3 M and RO(C 2 H 4 O) x SO 3 M wherein R is alkyl or alkenyl of from about 10 to 20 carbon atoms, x is 1 to about 10 and M is a water soluble cation such as ammonium, sodium, potassium, or triethanolamine cation.
[0091] Another type of anionic surfactant which may be used in the compositions of the invention are water soluble salts of organic, sulfuric acid reaction products of the general formula:
R 1 —SO 3 -M
wherein R 1 is a straight or branched chain, saturated aliphatic hydrocarbon radical having from about 8 to about 24 carbon atoms, preferably 12 to about 18 carbon atoms; and M is a cation. Examples of such anionic surfactants are salts of organic sulfuric acid reaction products of hydrocarbons such as n-paraffins having 8 to 24 carbon atoms, and a sulfonating agent, such as sulfur trioxide.
[0092] Also suitable as anionic surfactants are reaction products of fatty acids esterified with isethionic acid and neutralized with sodium hydroxide, or fatty acids reacted with alkanolamines or ammonium hydroxides. The fatty acids may be derived from coconut oil, for example. Examples of fatty acids also include lauric acid, stearic acid, oleic acid, palmitic acid, and so on.
[0093] In addition, succinates and succinimates are suitable anionic surfactants. This class includes compounds such as disodium N-octadecylsulfosuccinate; tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinate; and esters of sodium sulfosuccinic acid e.g. the dihexyl ester of sodium sulfosuccinic acid, the dioctyl ester of sodium sulfosuccinic acid, and the like.
[0094] Other suitable anionic surfactants include olefin sulfonates having about 12 to 24 carbon atoms. The term “olefin sulfonate” means a compound that can be produced by sulfonation of an alpha olefin by means of uncomplexed sulfur trioxide, followed by neutralization of the acid reaction mixture in conditions such that any sultones, which have been formed in the reaction are hydrolyzed to give the corresponding hydroxy-alkanesulfonates. The alpha olefin from which the olefin sulfonate is derived is a mono-olefin having about 12 to 24 carbon atoms, preferably about 14 to 16 carbon atoms.
[0095] Other classes of suitable anionic organic surfactants are the beta-alkoxy alkane sulfonates or water soluble soaps thereof, such as the salts of C 10-20 fatty acids, for example coconut and tallow based soaps. Preferred salts are ammonium, potassium, and sodium salts.
[0096] Still another class of anionic surfactants include N-acyl amino acid surfactants and salts thereof (alkali, alkaline earth, and ammonium salts) having the formula:
wherein R 1 is a C 8-24 alkyl or alkenyl radical, preferably C 10-18 ; R 2 is H, C 1-4 alkyl, phenyl, or —CH 2 COOM; R 3 is CX 2 — or C 1-2 alkoxy, wherein each X independently is H or a C 1-6 alkyl or alkylester, n is from 1 to 4, and M is H or a salt forming cation as described above. Examples of such surfactants are the N-acyl sarcosinates, including lauroyl sarcosinate, myristoyl sarcosinate, cocoyl sarcosinate, and oleoyl sarcosinate, preferably in sodium or potassium forms.
[0097] 3. Cationic, Zwitterionic or Betaine Surfactants
[0098] Certain types of amphoteric, zwitterionic, or cationic surfactants may also be used in the compositions. Descriptions of such surfactants are set forth in U.S. Pat. No. 5,843,193, which is hereby incorporated by reference in its entirety.
[0099] Amphoteric surfactants that can be used in the compositions of the invention are generally described as derivatives of aliphatic secondary or tertiary amines wherein one aliphatic radical is a straight or branched chain alkyl of 8 to 18 carbon atoms and the other aliphatic radical contains an anionic group such as carboxy, sulfonate, sulfate, phosphate, or phosphonate.
[0100] Suitable amphoteric surfactants may be imidazolinium compounds having the general formula:
wherein R′ is C 8-22 alkyl or alkenyl, preferably C 12-16 ; R 2 is hydrogen or CH 2 CO 2 M, R 3 is CH 2 CH 2 OH or CH 2 CH 2 OCH 2 CHCOOM; R 4 is hydrogen, CH 2 CH 2 OH, or CH 2 CH 2 OCH 2 CH 2 COOM, Z is CO 2 M or CH 2 CO 2 M, n is 2 or 3, preferably 2, M is hydrogen or a cation such as an alkali metal, alkaline earth metal, ammonium, or alkanol ammonium cation. Examples of such materials are marketed under the tradename MIRANOL, by Miranol, Inc.
[0101] Also, suitable amphoteric surfactants are monocarboxylates or dicarboxylates such as cocamphocarboxypropionate, cocoamphocarboxypropionic acid, cocamphocarboxyglycinate, and cocoamphoacetate.
[0102] Other types of amphoteric surfactants include aminoalkanoates of the formula
R—NH(CH 2 ) n COOM
or iminodialkanoates of the formula:
R—N[(CH 2 ) m COOM] 2
and mixtures thereof; wherein n and m are 1 to 4, R is C 8-22 alkyl or alkenyl, and M is hydrogen, alkali metal, alkaline earth metal, ammonium or alkanolammonium. Examples of such amphoteric surfactants include n-alkylaminopropionates and n-alkyliminodipropionates, which are sold under the trade name MIRATAINE by Miranol, Inc. or DERIPHAT by Henkel, for example N-lauryl-beta-amino propionic acid, N-lauryl-beta-imino-dipropionic acid, or mixtures thereof.
[0103] Zwitterionic surfactants are also suitable for use in the compositions of the invention. The general formula for such surfactants is:
wherein R 2 contains an alkyl, alkenyl or hydroxy alkyl radical of from about 8 to about 18 carbon atoms, from 0 to about 10 ethylene oxide moieties and 0 or 1 glyceryl moiety; Y is selected from the group consisting of nitrogen, phosphorus, and sulfur atoms; R 3 is an alkyl or monohydroxyalkyl group containing about 1 to 3 carbon atoms; X is 1 when Y is a sulfur atom, and 2 when Y is a nitrogen or phosphorus atom; R 4 is an alkylene or hydroxyalkylene of from about 1 to about 4 carbon atoms, and Z is a radical selected from the group consisting of carboxylate, sulfonate, sulfate, phosphonate, and phosphate groups.
[0104] Zwitterionic surfactants include betaines, for example higher alkyl betaines such as coco dimethyl carboxymethyl betaine, lauryl dimethyl carboxymethyl betaine, lauryl dimethyl alphacarboxyethyl betaine, cetyl dimethyl carboxymethyl betaine, lauryl bis-(2-hydroxyethyl)carboxymethyl betaine, stearyl bis-(2-hydroxypropyl)carboxymethyl betaine, oleyl dimethyl gamma-carboxylethyl betaine, and mixtures thereof. Also suitable are sulfo- and amido-betaines such as coco dimethyl sulfopropyl betaine, stearyl dimethyl sulfopropyl betaine, and the like.
[0105] C. Sunscreens
[0106] 1. UVA Chemical Sunscreens
[0107] If desired, the composition may comprise one or more UVA sunscreens. The term “UVA sunscreen” means a chemical compound that blocks UV radiation in the wavelength range of about 320 to 400 nm. Preferred UVA sunscreens are dibenzoylmethane compounds having the general formula:
wherein R 1 is H, OR and NRR wherein each R is independently H, C 1-20 straight or branched chain alkyl; R 2 is H or OH; and R 3 is H, C 1-20 straight or branched chain alkyl.
[0108] Preferred is where R 1 is OR where R is a C 1-20 straight or branched alkyl, preferably methyl; R 2 is H; and R 3 is a C 1-20 straight or branched chain alkyl, more preferably, butyl.
[0109] Examples of suitable UVA sunscreen compounds of this general formula include 4-methyldibenzoylmethane, 2-methyldibenzoylmethane, 4-isopropyldibenzoylmethane, 4-tert-butyldibenzoylmethane, 2,4-dimethyldibenzoylmethane, 2,5-dimethyldibenzoylmethane, 4,4′diisopropylbenzoylmethane, 4-tert-butyl-4′-methoxydibenzoylmethane, 4,4′-diisopropylbenzoylmethane, 2-methyl-5-isopropyl-4′-methoxydibenzoymethane, 2-methyl-5-tert-butyl-4′-methoxydibenzoylmethane, and so on. Particularly preferred is 4-tert-butyl-4′-methoxydibenzoylmethane, also referred to as Avobenzone. Avobenzone is commercial available from Givaudan-Roure under the trademark Parsol 1789, and Merck & Co. under the tradename Eusolex 9020.
[0110] The composition may contain from about 0.001-20%, preferably 0.005-5%, more preferably about 0.005-3% by weight of the composition of UVA sunscreen. In the preferred embodiment of the invention the UVA sunscreen is Avobenzone, and it is present at not greater than about 3% by weight of the total composition.
[0111] 2. UVB Chemical Sunscreens
[0112] The term “UVB sunscreen” means a compound that blocks UV radiation in the wavelength range of from about 290 to 320 nm. A variety of UVB chemical sunscreens exist including α-cyano-β,β-diphenyl acrylic acid esters as set forth in U.S. Pat. No. 3,215,724, which is hereby incorporated by reference in its entirety. One particular example of a α-cyano-β,β-diphenyl acrylic acid ester is Octocrylene, which is 2-ethylhexyl 2-cyano-3,3-diphenylacrylate. In certain cases the composition may contain no more than about 10% by weight of the total composition of octocrylene. Suitable amounts range from about 0.001-10% by weight. Octocrylene may be purchased from BASF under the tradename Uvinul N-539.
[0113] Other suitable sunscreens include benzylidene camphor derivatives as set forth in U.S. Pat. No. 3,781,417, which is hereby incorporated by reference in its entirety. Such benzylidene camphor derivatives have the general formula:
wherein R is p-tolyl or styryl, preferably styryl. Particularly preferred is 4-methylbenzylidene camphor, which is a lipid soluble UVB sunscreen compound sold under the tradename Eusolex 6300 by Merck.
[0114] Also suitable are cinnamate derivatives having the general formula:
wherein R and R 1 are each independently a C 1-20 straight or branched chain alkyl. Preferred is where R is methyl and R 1 is a branched chain C 1-10 , preferably C 8 alkyl. The preferred compound is ethylhexyl methoxycinnamate, also referred to as Octoxinate or octyl methoxycinnamate. The compound may be purchased from Givaudan Corporation under the tradename Parsol MCX, or BASF under the tradename Uvinul MC 80. Also suitable are mono-, di-, and triethanolamine derivatives of such methoxy cinnamates including diethanolamine methoxycinnamate. Cinoxate, the aromatic ether derivative of the above compound is also acceptable. If present, the Cinoxate should be found at no more than about 3% by weight of the total composition.
[0115] Also suitable as UVB screening agents are various benzophenone derivatives having the general formula:
wherein R through Rg are each independently H, OH, NaO 3 S, SO 3 H, SO 3 Na, Cl, R″, OR″ where R″ is C 1-20 straight or branched chain alkyl. Examples of such compounds include Benzophenone 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12. Particularly preferred is where the benzophenone derivative is Benzophenone 3 (also referred to as Oxybenzone), Benzophenone 4 (also referred to as Sulisobenzone), Benzophenone 5 (Sulisobenzone Sodium), and the like. Most preferred is Benzophenone 3.
[0116] Also suitable are certain menthyl salicylate derivatives having the general formula:
wherein R 1 , R 2 , R 3 , and R 4 are each independently H, OH, NH 2 , or C 1-20 straight or branched chain alkyl. Particularly preferred is where R 1 , R 2 , and R 3 are methyl and R 4 is hydroxyl or NH 2 , the compound having the name homomenthyl salicylate (also known as Homosalate) or menthyl anthranilate. Homosalate is available commercially from Merck under the tradename Eusolex HMS and menthyl anthranilate is commercially available from Haarmann & Reimer under the tradename Heliopan. If present, the Homosalate should be found at no more than about 15% by weight of the total composition.
[0117] Various amino benzoic acid derivatives are suitable UVB absorbers including those having the general formula:
wherein R 1 , R 2 , and R 3 are each independently H, C 1-20 straight or branched chain alkyl which may be substituted with one or more hydroxy groups. Particularly preferred is wherein R 1 is H or C 1-8 straight or branched alkyl, and R 2 and R 3 are H, or C 1-8 straight or branched chain alkyl. Particularly preferred are PABA, ethyl hexyl dimethyl PABA (Padimate O), ethyldihydroxypropyl PABA, and the like. If present Padimate O should be found at no more than about 8% by weight of the total composition.
[0118] Salicylate derivatives are also acceptable UVB absorbers. Such compounds have the general formula:
wherein R is a straight or branched chain alkyl, including derivatives of the above compound formed from mono-, di-, or triethanolamines. Particular preferred are octyl salicylate, TEA-salicylate, DEA-salicylate, and mixtures thereof.
[0119] Generally, the amount of the UVB chemical sunscreen present may range from about 0.001-45%, preferably 0.005-40%, more preferably about 0.01-35% by weight of the total composition.
[0120] 3. Physical Sunscreens
[0121] The composition may also include one or more physical sunscreens. The term “physical sunscreen” means a material that is generally particulate in form that is able to block UV rays by forming an actual physical block on the skin. Examples of particulates that serve as solid physical sunblocks include titanium dioxide, zinc oxide and the like in particle sizes ranging from about 0.001-150 microns.
[0122] If desired, the compositions of the invention may be formulated to have a certain SPF (sun protective factor) values ranging from about 1-50, preferably about 2-45, most preferably about 5-30. Calculation of SPF values is well known in the art. Preferably, the claimed compositions have SPF values greater than 4.
[0123] D. Humectants
[0124] If desired, the compositions of the invention comprise 0.01-30%, preferably 0.5-25%, more preferably 1-20% by weight of the total composition of one or more humectants. Suitable humectants include materials such as glycols, sugars, and the like. Suitable glycols include polyethylene and polypropylene glycols such as PEG 4-240, which are polyethylene glycols having from 4 to 240 repeating ethylene oxide units; as well as C 1-6 alkylene glycols such as propylene glycol, butylene glycol, and the like. Suitable sugars, some of which are also polyhydric alcohols, are also suitable humectants. Examples of such sugars include glucose, fructose, honey, hydrogenated honey, inositol, maltose, mannitol, maltitol, sorbitol, sucrose, xylitol, xylose, and so on. Preferably, the humectants used in the composition of the invention are C 1-6 , preferably C 2-4 alkylene glycols, most particularly butylene glycol.
[0125] E. Botanical Extracts
[0126] It may be desirable to include one or more botanical extracts in the compositions. If so, suggested ranges are from about 0.0001 to 10%, preferably about 0.0005 to 8%, more preferably about 0.001 to 5% by weight of the total composition. Suitable botanical extracts include extracts from plants (herbs, roots, flowers, fruits, seeds) such as flowers, fruits, vegetables, and so on, including acacia (dealbata, famesiana, senegal), acer saccharinum (sugar maple), acidopholus, acorus, aesculus, agaricus, agave, agrimonia, algae, aloe, citrus, brassica, cinnamon, orange, apple, blueberry, cranberry, peach, pear, lemon, lime, pea, seaweed, green tea, chamomile, willowbark, mulberry, poppy, and those set forth on pages 1646 through 1660 of the CTFA Cosmetic Ingredient Handbook, Eighth Edition, Volume 2. Further specific examples include, but are not limited to, Glycyrrhiza Glabra, Salix Nigra, Macrocycstis Pyrifera, Pyrus Malus, Saxifraga Sarmentosa, Vitis Vinifera, Morus Nigra, Scutellaria Baicalensis, Anthemis Nobilis, Salvia Sclarea, Rosmarinus Officianalis, Citrus Medica Limonum, and mixtures thereof.
[0127] F. Structuring Agents
[0128] The compositions of the invention may comprise one more structuring agents. The term “structuring agent” means an ingredient or combination of ingredients that increase the viscosity of, or thicken, the composition. Suggested ranges of structuring agent, if present, range from about 0.01-65%, preferably about 0.05-50%, more preferably about 0. 1-45% by weight of the total composition. If the composition is in the form of an emulsion, the structuring agent may be found in the oil phase, water phase, or both phases. In the event the composition is anhydrous, the structuring agent may be found in the oil phase of the composition, or as part of the particulate phase, etc.
[0129] 1. Montmorillonite Minerals
[0130] One type of structuring agent that may be used in the composition comprises natural or synthetic montmorillonite minerals such as hectorite, bentonite, and quaternized derivatives thereof, which are obtained by reacting the minerals with a quaternary ammonium compound, such as stearalkonium bentonite, hectorites, quaternized hectorites such as Quaternium-18 hectorite, attapulgite, carbonates such as propylene carbonate, bentones, and the like. Particularly preferred is Quaternium-18 hectorite.
[0131] 2. Associative Thickeners
[0132] Also suitable as structuring agents are various polymeric compounds known in the art as associative thickeners. Suitable associative thickeners generally contain a hydrophilic backbone and hydrophobic side groups. Examples of such thickeners include polyacrylates with hydrophobic side groups, cellulose ethers with hydrophobic side groups, polyurethane thickeners. Examples of hydrophobic side groups are long chain alkyl groups such as dodecyl, hexadecyl, or octadecyl; alkylaryl groups such as octylphenyl or nonyphenyl. Further specific examples include hydroxypropylcellulose, hydroxypropylethylcellulose, cellulose gums, and the like.
[0133] 3. Silicas and Silicates
[0134] Another type of structuring agent that may be used in the compositions are silicas, silicates, silica silylate, and alkali metal or alkaline earth metal derivatives thereof. These silicas and silicates are generally found in the particulate form and include silica, silica silylate, magnesium aluminum silicate, and the like.
[0135] 4. Silicone Elastomers
[0136] Also suitable as structuring agents are cross-linked organosiloxane compounds also known as silicone elastomers. Such elastomers are generally prepared by reacting a dimethyl methylhydrogen siloxane with a crosslinking group comprised of a siloxane having an alkylene group having terminal olefinic unsaturation, or with an organic group having an alpha or omega diene. Examples of suitable silicone elastomers for use as thixotropic agents include Dow Corning 9040, sold by Dow Corning, and various elastomeric silicones sold by Shin-Etsu under the KSG tradename including KSG 15, KSG 16, KSG 19 and so on.
[0137] 5. Natural or Synthetic Organic Waxes
[0138] Suitable structuring agents include natural or synthetic waxes. A variety of waxes are suitable including animal, vegetable, mineral, or silicone waxes. Generally such waxes have a melting point ranging from about 28 to 125° C., preferably about 30 to 100° C. Examples of waxes include acacia, beeswax, ceresin, cetyl esters, flower wax, citrus wax, carnauba wax, jojoba wax, japan wax, polyethylene, microcrystalline, rice bran, lanolin wax, mink, montan, bayberry, ouricury, ozokerite, palm kernel wax, paraffin, avocado wax, apple wax, shellac wax, clary wax, spent grain wax, candelilla, grape wax, and polyalkylene glycol derivatives thereof such as PEG 6-20 beeswax, or PEG-12 carnauba wax; or fatty acids or fatty alcohols, including esters thereof, such as hydroxystearic acids (for example 12-hydroxy stearic acid), tristearin, tribehenin, and so on.
[0139] 6. Silicone Waxes
[0140] Also suitable are various types of silicone waxes, referred to as alkyl silicones, which are polymers that comprise repeating dimethylsiloxy units in combination with one or more methyl-long chain alkyl siloxy units wherein the long chain alkyl is generally a fatty chain that provides a wax-like characteristic to the silicone such that is a solid or semi-solid at room temperature. Such silicones include, but are not limited to stearoxydimethicone, behenoxy dimethicone, stearyl dimethicone, cetearyl dimethicone, and so on. Suitable waxes are set forth in U.S. Pat. No. 5,725,845, which is hereby incorporated by reference in its entirety.
[0141] 7. Polyamides and Silicone Polyamides
[0142] Also suitable as structuring agents are various types of polyamides or silicone polyamides including those set forth in U.S. patent publication Nos. 2002/0114773 or 2003/0072730, both of which are hereby incorporated by reference in their entirety.
[0143] Silicone polyamides include those having moieties of the general formula:
wherein:
X is a linear or branched alkylene having from about 1-30 carbon atoms, R 1 , R 2 , R 3 , and R 4 are each independently C 1-30 straight or branched chain alkyl which may be substituted with one or more hydroxyl or halogen groups; phenyl which may be substituted with one or more C 1-30 alkyl groups, halogen, hydroxyl, or alkoxy groups; or a siloxane chain having the general formula:
Y is: (a) a linear or branched alkylene having from about 1-40 carbon atoms which may be substituted with (i) one or more amide groups having the general formula R 1 CONR 1 , or (ii) C 5-6 cyclic ring, or (iii) phenylene which may be substituted with one or more C 1-10 alkyl groups, or (iv) hydroxy, or (v) C 3-8 cycloalkane, or (vi) C 1-20 alkyl which may be substituted with one or more hydroxy groups, or (vii) C 1-10 alkyl amines; or (b) TR 5 R 6 R 7 wherein R 5 , R 6 , and R 7 , are each independently a C 1-10 linear or branched alkylene, and T is CR 8 wherein R 8 is hydrogen, a trivalent atom N, P, or Al, or a C 1-30 straight or branched chain alkyl which may be substituted with one or more hydroxyl or halogen groups; phenyl which may be substituted with one or more C 1-30 alkyl groups, halogen, hydroxyl, or alkoxy groups; or a siloxane chain having the general formula:
and a and b are each independently sufficient to provide a silicone polyamide polymer having a melting point ranging from about 60 to 120° C., preferably about 85 to 105° C. and a molecular weight ranging from about 40,000 to 500,000 Daltons, preferably about 65,000 to 149,000 Daltons.
[0150] Preferred is where R 1 , R 2 , R 3 , and R 4 are C 1-10 , preferably methyl; and X and Y is a linear or branched alkylene. Preferred are silicone polyamides having the general formula:
wherein a, b, and x are each independently sufficient to provide a silicone polyamide polymer having a melting point ranging from about 60 to 120° C., preferably about 85 to 105° C. and a molecular weight ranging from about 40,000 to 500,000 Daltons, preferably about 65,000 to 149,000 Daltons. One type of silicone polyamide that may be used in the compositions of the invention may be purchased from Dow Corning Corporation under the tradename Dow Corning 2-8178 gellant which has the INCI name nylon-611/dimethicone copolymer which is sold in a composition containing PPG-3 myristyl ether.
[0151] G. Particulate Materials
[0152] The compositions of the invention may contain particulate materials in the form of pigments, inert particulates, or mixtures thereof. If present, suggested ranges are from about 0.01-75%, preferably about 0.05-70%, more preferably about 0.1-65% by weight of the total composition. In the case where the composition may comprise mixtures of pigments and powders, suitable ranges include about 0.01-75% pigment and 0.1-75% powder, such weights by weight of the total composition.
[0153] 1. Powders
[0154] The particulate matter may be colored or non-colored (for example white) non-pigmentatious powders. Suitable non-pigmentatious powders include bismuth oxychloride, titanated mica, fumed silica, spherical silica, polymethylmethacrylate, micronized teflon, boron nitride, acrylate copolymers, aluminum silicate, aluminum starch octenylsuccinate, bentonite, calcium silicate, cellulose, chalk, corn starch, diatomaceous earth, fuller's earth, glyceryl starch, hectorite, hydrated silica, kaolin, magnesium aluminum silicate, magnesium trisilicate, maltodextrin, montmorillonite, microcrystalline cellulose, rice starch, silica, talc, mica, titanium dioxide, zinc laurate, zinc myristate, zinc rosinate, alumina, attapulgite, calcium carbonate, calcium silicate, dextran, kaolin, nylon, silica silylate, silk powder, sericite, soy flour, tin oxide, titanium hydroxide, trimagnesium phosphate, walnut shell powder, or mixtures thereof. The above mentioned powders may be surface treated with lecithin, amino acids, mineral oil, silicone, or various other agents either alone or in combination, which coat the powder surface and render the particles more lipophilic in nature.
[0155] 2. Pigments
[0156] The particulate materials may comprise various organic and/or inorganic pigments. The organic pigments are generally various aromatic types including azo, indigoid, triphenylmethane, anthroquinone, and xanthine dyes which are designated as D&C and FD&C blues, browns, greens, oranges, reds, yellows, etc. Organic pigments generally consist of insoluble metallic salts of certified color additives, referred to as the Lakes. Inorganic pigments include iron oxides, ultramarines, chromium, chromium hydroxide colors, and mixtures thereof. Iron oxides of red, blue, yellow, brown, black, and mixtures thereof are suitable
[0157] H. Film Forming Polymers
[0158] The compositions of the invention may comprise one or more film forming polymers that aid in forming a film on the skin or provide other effects that lend beneficial properties to the formula. Examples of such film forming polymers include, but are not limited to those set forth below.
[0159] 1. Silicone Film Forming Polymers
[0160] (a) Siloxane Polymeric Resins and Gums
[0161] Siloxane polymeric resins that comprises tetrafunctional or trifunctional units either alone or in combination with monofunctional units are suitable silicone film forming polymers for use in the composition. The term “siloxane polymeric resin” means that the siloxane is a polymer, or is comprised of repeating units or “mers”.
[0162] The term “resin” means that the siloxane polymer provides substantive, resinous, film forming properties when applied to skin. In the context of this invention, the term “resin” will mean a siloxane containing enough cross-linking to provide substantive, film forming properties. The term cross-linking means a moiety where the silicon atom is bonded to at least three, preferably four oxygen atoms when the moiety is polymerized with another siloxane unit.
[0163] The term “film forming” means that the siloxane resin is capable of forming a film, in particular, a substantive film, on the keratinous surface to which it is. applied.
[0164] The term monofunctional unit means a siloxy unit that contains one silicon atom bonded to one oxygen atom, with the remaining three substituents on the silicon atom being other than oxygen. In particular, in a monofunctional siloxy unit, the oxygen atom present is shared by 2 silicon atoms when the monofunctional unit is polymerized with one or more of the other units. In silicone nomenclature used by those skilled in the art, a monofunctional siloxy unit is designated by the letter “M”, and means a unit having the general formula:
R 1 R 2 R 3 SiO 1/2
wherein R 1 , R 2 , and R 3 are each independently C 1-30 , preferably C 1-10 , more preferably CI 4 straight or branched chain alkyl, which may be substituted with phenyl or one or more hydroxyl groups; phenyl; alkoxy (preferably C 1-22 , more preferably C 1-6 ); or hydrogen. The SiO 1/2 designation means that the oxygen atom in the monofunctional unit is bonded to, or shared, with another silicon atom when the monofunctional unit is polymerized with one or more of the other types of units. For example, when R 1 , R 2 , and R 3 are methyl the resulting monofunctional unit is of the formula:
[0165] When this monofunctional unit is polymerized with one or more of the other units the oxygen atom will be shared by another silicon atom, i.e. the silicon atom in the monofunctional unit is bonded to ½ of this oxygen atom.
[0166] The term “difunctional siloxy unit” is generally designated by the letter “D” in standard silicone nomenclature. If the D unit is substituted with substituents other than methyl the “D” designation is sometimes used, which indicates a substituent other than methyl. For purposes of this disclosure, a “D” unit has the general formula:
R 1 R 2 SiO 2/2
wherein R 1 and R 2 are defined as above. The SiO 2/2 designation means that the silicon atom in the difunctional unit is bonded to two oxygen atoms when the unit is polymerized with one or more of the other units. For example, when R 1 and R 2 , are methyl the resulting difunctional unit is of the formula:
When this difunctional unit is polymerized with one or more of the other units the silicon atom will be bonded to two oxygen atoms, i.e. will share two one-halves of an oxygen atom.
[0167] The term “trifunctional siloxy unit” is generally designated by the letter “T” in standard silicone nomenclature. A “T” unit has the general formula:
R 1 SiO 3/2
wherein R 1 is as defined above. The SiO 3/2 designation means that the silicon atom is bonded to three oxygen atoms when the unit is copolymerized with one or more of the other units. For example when R 1 is methyl the resulting trifunctional unit is of the formula:
When this trifunctional unit is polymerized with one or more of the other units, the silicon atom shares three oxygen atoms with other silicon atoms, i.e. will share three halves of an oxygen atom.
[0168] The term “tetrafunctional siloxy unit” is generally designated by the letter “Q” in standard silicone nomenclature. A “Q” unit has the general formula:
SiO 4/2
[0169] The SiO 4/2 designation means that the silicon shares four oxygen atoms (i.e., four halves) with other silicon atoms when the tetrafunctional unit is polymerized with one or more of the other units. The SiO 4/2 unit is best depicted as follows:
[0170] The film forming siloxane resins that may be used in the compositions of the invention comprises D, T or Q units either alone or in combination with M units. In addition, there may be one or more of the other types of units present in the polymer.
[0171] The film forming polymeric siloxane resin may be a liquid, semi-solid, or solid at room temperature. Preferably, the siloxane polymeric resin is a semi-solid or solid at room temperature.
[0172] Typically T or MT silicones are referred to as silsesquioxanes, and in the case where M units are present methylsilsesquioxanes. Preferred are T silicones having the following general formula:
(R 1 SiO 3/2 )x
where x ranges from about 1 to 100,000, preferably about 1-50,000, more preferably about 1-10,000, and wherein R 1 is as defined above. Such MT silicones are generally referred to as polymethylsilsesquioxane which are silsesquioxanes containing methyl groups.
[0173] Examples of specific polysilsesquioxanes that may be used are manufactured by Wacker Chemie under the Resin MK designation. This polysilsesquioxane is a polymer comprised of T units and, optionally one or more D (preferably dimethylsiloxy) units. This particularly polymer may have ends capped with ethoxy groups, and/or hydroxyl groups, which may be due to how the polymers are made, e.g. condensation in aqueous or alcoholic media. Other suitable polysilsesquioxanes that may be used as the film forming polymer include those manufactured by Shin-Etsu Silicones and include the “KR” series, e.g. KR-220L, 242A, and so on. These particular silicone resins may contain endcap units that are hydroxyl or alkoxy groups which may be present due to the manner in which such resins are manufactured.
[0174] Also suitable are MQ resins, which are siloxy silicate polymers having the following general formula:
wherein R, R′ and R″ are each independently a C 1-10 straight or branched chain alkyl or phenyl, and x and y are such that the ratio of (RR′R″) 3 SiOi/ 2 units to SiO 2 units ranges from about 0.5 to 1 to 1.5 to 1. Preferably R, R′ and R″ are a C 1-6 alkyl, and more preferably are methyl and x and y are such that the ratio of (CH 3 ) 3 SiO 1/2 units to SiO 2 units is about 0.75 to 1. Most preferred is this trimethylsiloxysilicate containing 2.4 to 2.9 weight percent hydroxyl groups which is formed by the reaction of the sodium salt of silicic acid, chlorotrimethylsilane, and isopropyl alcohol. The manufacture of trimethylsiloxysilicate is set forth in U.S. Pat. Nos. 2,676,182; 3,541,205; and 3,836,437, all of which are hereby incorporated by reference. Trimethylsiloxysilicate as described is available from GE Silicones under the tradename SR-1000, which is a solid particulate material. Also suitable is Dow Corning 749 which is a mixture of volatile cyclic silicone and trimethylsiloxysilicate.
[0175] The film forming siloxane polymeric resins that may be used in the composition are made according to processes well known in the art. In general siloxane polymers are obtained by hydrolysis of silane monomers, preferably chlorosilanes. The chlorosilanes are hydrolyzed to silanols and then condensed to form siloxanes. For example, Q units are often made by hydrolyzing tetrachlorosilanes in aqueous or aqueous/alcoholic media to form the following:
The above hydroxy substituted silane is then condensed or polymerized with other types of silanol substituted units such as:
wherein n is 0-10, preferably 0-4.
[0176] Because the hydrolysis and condensation may take place in aqueous or aqueous/alcoholic media wherein the alcohols are preferably lower alkanols such as ethanol, propanol, or isopropanol, the units may have residual hydroxyl or alkoxy functionality as depicted above. Preferably, the resins are made by hydrolysis and condensation in aqueous/alcoholic media, which provides resins that have residual silanol and alkoxy functionality. In the case where the alcohol is ethanol, the result is a resin that has residual hydroxy or ethoxy functionality on the siloxane polymer. The silicone film forming polymers used in the compositions of the invention are generally made in accordance with the methods set forth in Silicon Compounds ( Silicones ), Bruce B. Hardman, Arnold Torkelson, General Electric Company, Kirk-Othmer Encyclopedia of Chemical Technology, Volume 20, Third Edition, pages 922-962, 1982, which is hereby incorporated by reference in its entirety.
[0177] Also suitable are linear, high molecular weight silicones that are semi-solids, solids, or gums at room temperature. Examples of such silicones include dimethicones having viscosities ranging from about 100,000 to 10 million, or 500,000 to 10 million centipoise or dimethicone copolyols having the same viscosity range.
[0178] Also suitable are silicone esters as disclosed in U.S. Pat. Nos. 4,725,658 and 5,334,737, which are hereby incorporated by reference. Such silicone esters comprise units of the general formula R a R E b SiO[ 4(a+b)/2] or R 13 x R E y SiO 1/2 , wherein R and R 13 are each independently an organic radical such as alkyl, cycloalkyl, or aryl, or, for example, methyl, ethyl, propyl, hexyl, octyl, decyl, aryl, cyclohexyl, and the like, a is a number ranging from 0 to 3, b is a number ranging from 0 to 3, a+b is a number ranging from 1 to 3, x is a number from 0 to 3, y is a number from 0 to 3 and the sum of x+y is 3, and wherein R E is a carboxylic ester containing radical. Preferred R E radicals are those wherein the ester group is formed of one or more fatty acid moieties (e.g. of about 2, often about 3 to 10 carbon atoms) and one or more aliphatic alcohol moieties (e.g. of about 10 to 30 carbon atoms). Examples of such acid moieties include those derived from branched-chain fatty acids such as isostearic, or straight chain fatty acids such as behenic. Examples of suitable alcohol moieties include those derived from monohydric or polyhydric alcohols, e.g. normal alkanols such as n-propanol and branched-chain etheralkanols such as (3,3,3-trimethylolpropoxy)propane. Preferably the ester subgroup (i.e. the carbonyloxy radical) will be linked to the silicon atom by a divalent aliphatic chain that is at least 2 or 3 carbon atoms in length, e.g. an alkylene group or a divalent alkyl ether group. Most preferably that chain will be part of the alcohol moiety, not the acid moiety. Such silicones may be liquids or solids at room temperature.
[0179] (b). Copolymers of Silicone and Ethylenically Unsaturated Monomers
[0180] Another type of film forming polymer that may be used in the compositions of the invention is obtained by reacting silicone moieties with ethylenically unsaturated monomers. The resulting copolymers may be graft or block copolymers. The term “graft copolymer” is familiar to one of ordinary skill in polymer science and is used herein to describe the copolymers which result by adding or “grafting” polymeric side chain moieties (i.e. “grafts”) onto another polymeric moiety referred to as the “backbone”. The backbone may have a higher molecular weight than the grafts. Thus, graft copolymers can be described as polymers having pendant polymeric side chains, and which are formed from the “grafting” or incorporation of polymeric side chains onto or into a polymer backbone. The polymer backbone can be a homopolymer or a copolymer. The graft copolymers are derived from a variety of monomer units.
[0181] One type of polymer that may be used as the film forming polymer is a vinyl-silicone graft or block copolymer having the formula:
wherein G 5 represents monovalent moieties which can independently be the same or different selected from the group consisting of alkyl, aryl, aralkyl, alkoxy, alkylamino, fluoroalkyl, hydrogen, and -ZSA;
wherein A represents a vinyl polymeric segment consisting essentially of a polymerized free radically polymerizable monomer, and Z is a divalent linking group such as C 1-10 alkylene, aralkylene, arylene, and alkoxylalkylene, most preferably Z is methylene or propylene, G 6 is a monovalent moiety which can independently be the same or different selected from the group consisting of alkyl, aryl, aralkyl, alkoxy, alkylamino, fluoroalkyl, hydrogen, and -ZSA; G 2 comprises A; G 4 comprises A; R 1 is a monovalent moiety which can independently be the same or different and is selected from the group consisting of alkyl, aryl, aralkyl, alkoxy, alkylamino, fluoroalkyl, hydrogen, and hydroxyl; but preferably C 14 alkyl or hydroxyl, and most preferably methyl. R 2 is independently the same or different and is a divalent linking group such as C 1-10 alkylene, arylene, aralkylene, and alkoxyalkylene, preferably C 1-3 alkylene or C 7-10 aralkylene, and most preferably —CH 2 — or 1,3-propylene, R 3 is a monovalent moiety which is independently alkyl, aryl, aralkyl, alkoxy, alkylamino, fluoroalkyl, hydrogen, or hydroxyl, preferably C 1-4 alkyl or hydroxyl, most preferably methyl; R 4 is independently the same or different and is a divalent linking group such as C 1-10 alkylene, arylene, aralkylene, alkoxyalkylene, but preferably C 1-3 alkylene and C 7-10 alkarylene, most preferably —CH 2 — or 1,3-propylene, x is an integer of 0-3; y is an integer of 5 or greater; preferably 10 to 270, and more preferably 40-270; and q is an integer of 0-3.
[0193] These polymers are described in U.S. Pat. No. 5,468,477, which is hereby incorporated by reference. Most preferred is poly(dimethylsiloxane)-g-poly(isobutyl methacrylate), which is manufactured by 3-M Company under the tradename VS 70 IBM. This polymer may be purchased in the dry particulate form, or as a solution where the polymer is dissolved in one or more solvents such as isododecane. Preferred is where the polymer is in dry particulate form, and as such it can be dissolved in one or more of the liquids comprising the liquid carrier. This polymer has the CTFA name Polysilicone-6.
[0194] Another type of such a polymer comprises a vinyl, methacrylic, or acrylic backbone with pendant siloxane groups and pendant fluorochemical groups. Such polymers preferably comprise repeating A, C, D and optionally B monomers wherein:
A is at least one free radically polymerizable acrylic or methacrylic ester of a 1,1,-dihydroperfluoroalkanol or analog thereof, omega-hydridofluoroalkanols, fluoroalkylsulfonamido alcohols, cyclic fluoroalkyl alcohols, and fluoroether alcohols, B is at least one reinforcing monomer copolymerizable with A, C is a monomer having the general formula X(Y)nSi(R)3-mZ m wherein X is a vinyl group copolymerizable with the A and B monomers, Y is a divalent linking group which is alkylene, arylene, alkarylene, and aralkylene of 1 to 30 carbon atoms which may incorporate ester, amide, urethane, or urea groups, n is zero or 1; m is an integer of from 1 to 3, R is hydrogen, C 1-4 alkyl, aryl, or alkoxy, Z is a monovalent siloxane polymeric moiety; and D is at least one free radically polymerizable acrylate or methacrylate copolymer.
[0205] Such polymers and their manufacture are disclosed in U.S. Pat. Nos. 5,209,924 and 4,972,037, which are hereby incorporated by reference. More specifically, the preferred polymer is a combination of A, C, and D monomers wherein A is a polymerizable acrylic or methacrylic ester of a fluoroalkylsulfonamido alcohol, and where D is a methacrylic acid ester of a C 1-2 straight or branched chain alcohol, and C is as defined above. Most preferred is a polymer having moieties of the general formula:
wherein each of a, b, and c has a value in the range of 1 -100,000, n has a value preferably in the range of 1-1,000,000, and the terminal groups are selected from the group consisting of a C 1-20 straight or branched chain alkyl, aryl, and alkoxy and the like. These polymers may be purchased from Minnesota Mining and Manufacturing Company under the tradenames “Silicone Plus” polymers. Most preferred is poly(isobutyl methacrylate-co-methyl FOSEA)-g-poly(dimethylsiloxane) which is sold under the tradename SA 70-5 IBMMF.
[0206] Another suitable silicone acrylate copolymer is a polymer having a vinyl, methacrylic, or acrylic polymeric backbone with pendant siloxane groups. Such polymers as disclosed in U.S. Pat. Nos. 4,693,935, 4,981,903, 4,981,902, and which are hereby incorporated by reference. Preferably, these polymers are comprised of A, C, and optionally B monomers wherein:
A is at least one free radically polymerizable vinyl, methacrylate, or acrylate monomer; B, when present, is at least one reinforcing monomer copolymerizable with A, C is a monomer having the general formula:
X(Y) n Si(R) 3-m Z m
wherein:
X is a vinyl group copolymerizable with the A and B monomers; Y is a divalent linking group; n is zero or 1; m is an integer of from 1 to 3; R is hydrogen, C 1-10 alkyl, substituted or unsubstituted phenyl, C 1-10 alkoxy; and Z is a monovalent siloxane polymeric moiety.
[0216] Examples of A monomers are lower to intermediate methacrylic acid esters of C 1-12 straight or branched chain alcohols, styrene, vinyl esters, vinyl chloride, vinylidene chloride, acryloyl monomers, and so on.
[0217] The B monomer, if present, is a polar acrylic or methacrylic monomer having at least one hydroxyl, amino, or ionic group (such as quaternary ammonium, carboxylate salt, sulfonic acid salt, and so on).
[0218] The C monomer is as above defined.
[0219] Examples of other suitable copolymers that may be used herein, and their method of manufacture, are described in detail in U.S. Pat. No. 4,693,935, Mazurek and U.S. Pat. No. 4,728,571, Clemens et al., both of which are incorporated herein by reference. Additional grafted polymers are also disclosed in EPO application 90307528.1, published as EPO application 0 408 311, U.S. Pat. No. 5,061,481, Suzuki et al., U.S. Pat. No. 5,106,609, Bolich et al., U.S. Pat. No. 5,100,658, Bolich et al., U.S. Pat. No. 5,100,657, Ansher-Jackson et al., U.S. Pat. No. 5,104,646, Bolich et al., U.S. Pat. No. 5,618,524, issued Apr. 8, 1997, all of which are incorporated by reference herein in their entirety.
[0220] (c). Synthetic Organic Polymers
[0221] Also suitable for use as film forming polymers in the compositions are polymers made by polymerizing one or more ethylenically unsaturated monomers. The final polymer may be a homopolymer, copolymer, terpolymer, or graft or block copolymer, and may contain monomeric units such as acrylic acid, methacrylic acid or their simple esters, styrene, ethylenically unsaturated monomer units such as ethylene, propylene, butylene, etc., vinyl monomers such as vinyl chloride, styrene, and so on.
[0222] In some cases, polymers containing one or more monomers which are esters of acrylic acid or methacrylic acid, including aliphatic esters of methacrylic acid like those obtained with the esterification of methacrylic acid or acrylic acid with an aliphatic alcohol of 1 to 30, preferably 2 to 20, more preferably 2 to 8 carbon atoms. If desired, the aliphatic alcohol may have one or more hydroxy groups are particularly suitable. Also suitable are methacrylic acid or acrylic acid esters esterified with moieties containing alicyclic or bicyclic rings such as cyclohexyl or isobomyl, for example.
[0223] The ethylenically unsaturated monomer may be mono-, di-, tri-, or polyftunctional as regards the addition-polymerizable ethylenic bonds. A variety of ethylenically unsaturated monomers are suitable.
[0224] Examples of suitable monofunctional ethylenically unsaturated monomers include those of the formula:
wherein R 1 is H, a C 1-30 straight or branched chain alkyl, aryl, or aralkyl; R 2 is a pyrrolidone, a C 1-30 straight or branched chain alkyl, or a substituted or unsubstituted aromatic, alicyclic, or bicyclic ring where the substituents are C 1-30 straight or branched chain alkyl, or COOM or OCOM wherein M is H, a C 1-30 straight or branched chain alkyl, pyrrolidone, or a substituted or unsubstituted aromatic, alicyclic, or bicyclic ring where the substituents are C 1-30 straight or branched chain alkyl which may be substituted with one or more hydroxyl groups, or [(CH 2 ) m O]nH wherein m is 1-20, and n is 1-200.
[0225] More specific examples include the monofunctional ethylenically unsaturated monomer is of Formula I, above, wherein R 1 is H or a C 1-30 alkyl, and R 2 is COOM or OCOM wherein M is a C 1-30 straight or branched chain alkyl which may be substituted with one or more hydroxy groups.
[0226] Further examples include where R 1 is H or CH 3 , and R 2 is COOM wherein M is a C 1-10 straight or branched chain alkyl which may be substituted with one or more hydroxy groups.
[0227] Di-, tri- and polyfunctional monomers, as well as oligomers, of the above monofunctional monomers may also be used to form the polymer. Suitable difunctional monomers include those having the general formula:
wherein R 3 and R 4 are each independently H, a C 1-30 straight or branched chain alkyl, aryl, or aralkyl; and X is [(CH 2 ) x O y ] z wherein x is 1-20, and y is 1-20, and z is 1-100. Particularly preferred are difunctional acrylates and methacrylates, such as the compound of Formula II above wherein R 3 and R4 are CH 3 and X is [(CH 2 ) x O y ] z wherein x is 1-4; and y is 1-6; and z is 1-10.
[0228] Trifunctional and polyfunctional monomers are also suitable for use in the polymerizable monomer to form the polymer used in the compositions of the invention. Examples of such monomers include acrylates and methacrylates such as trimethylolpropane trimethacrylate or trimethylolpropane triacrylate.
[0229] The polymers can be prepared by conventional free radical polymerization techniques in which the monomer, solvent, and polymerization initiator are charged over a 1-24 hour period of time, preferably 2-8 hours, into a conventional polymerization reactor in which the constituents are heated to about 60-175° C., preferably 80-100° C. The polymers may also be made by emulsion polymerization or suspension polymerization using conventional techniques. Also anionic polymerization or Group Transfer Polymerization (GTP) is another method by which the copolymers used in the invention may be made. GTP is well known in the art and disclosed in U.S. Pat. Nos. 4,414,372; 4,417,034; 4,508,880; 4,524,196; 4,581,428; 4,588,795; 4,598,161; 4,605,716; 4,605,716; 4,622,372; 4,656,233; 4,711,942; 4,681,918; and 4,822,859; all of which are hereby incorporated by reference.
[0230] Also suitable are polymers formed from the monomer of Formula I, above, which are cyclized, in particular, cycloalkylacrylate polymers or copolymers having the following general formulas:
wherein R 1 , R 2 , R 3 , and R 4 are as defined above. Typically such polymers are referred to as cycloalkylacrylate polymers. Such polymers are sold by Phoenix Chemical, Inc. under the tradename Giovarez AC-5099M. Giovarez has the chemical name isododecane acrylates copolymer and the polymer is solubilized in isododecane. The monomers mentioned herein can be polymerized with various types of organic groups such as propylene glycol, isocyanates, amides, etc.
[0231] One type of organic group that can be polymerized with the above monomers includes a urethane monomer. Urethanes are generally formed by the reaction of polyhydroxy compounds with diisocyanates, as follows:
wherein x is 1-1000.
[0232] Another type of monomer that may be polymerized with the above comprise amide groups, preferably having the the following formula:
wherein X and Y are each independently linear or branched alkylene having 1-40 carbon atoms, which-may be substituted with one or more amide, hydrogen, alkyl, aryl, or halogen substituents.
[0233] Another type of organic monomer may be alpha or beta pinenes, or terpenes, abietic acid, and the like.
[0234] One additional type of synthetic organic polymer that may be used in the compositions of the invention is obtained by polymerizing ethylenically unsaturated monomers which comprise vinyl ester groups either alone or in combination with other monomers including silicone monomers, other ethylenically unsaturated monomers, or organic groups such as amides, urethanes, glycols, and the like. The various types of monomers or moieties may be incorporated into the film forming polymer by way of free radical polymerization, addition polymerization, or by formation of grafts and blocks which are attached to the growing polymer chain according to processes known in the art.
[0235] Typically, this type of film forming polymer comprises vinyl ester monomers having the following general formula:
wherein M is H, or a straight or branched chain C 1-100 alkyl, preferably a C 1-150 alkyl, more preferably a C 1-45 alkyl which may be saturated or unsaturated, or substituted or unsubstituted, where the substituents include hydroxyl, ethoxy, amide or amine, halogen, alkyloxy, alkyloxycarbonyl, and the like. Preferably, M is H or a straight or branched chain alkyl having from 1 to 30 carbon atoms. The film forming polymer may be a homopolymer or copolymer having the vinyl ester monomers either alone or in combination with other ethylenically unsaturated monomers, organic groups, or silicone monomers.
[0236] Suitable other monomers that may be copolymerized with the vinyl ester monomer include those having siloxane groups, including but not limited to those of the formula:
wherein R and R′ are each independently a C1-30 straight or branched chain alkyl, phenyl, or trimethylsiloxy and n ranges from 1-1,000,000. The silicone monomers are preferably polymerized into a siloxane polymer then attached to the polymer chain by attaching a terminal organic group having olefinic unsaturation such as ethylene or propylene, to the siloxane, then reacting the unsaturated group with a suitable reactive site on the polymer to graft the siloxane chain to the polymer.
[0237] Also suitable are various types of organic groups that may be polymerized with the vinyl ester monomers including but not limited to urethane, amide, polyalkylene glycols, and the like as set forth above.
[0238] The vinyl ester monomers may also be copolymerized with other ethylenically unsaturated monomers that are not vinyl esters, including those set forth above.
[0239] (d). Natural Polymers
[0240] Also suitable for use are one or more naturally occurring polymeric materials such as resinous plant extracts including such as rosin, shellac, chitin, and the like.
[0241] I. Preservatives
[0242] The composition may contain 0.001-8%, preferably 0.01-6%, more preferably 0.05-5% by weight of the total composition of preservatives. A variety of preservatives are suitable, including such as benzoic acid, benzyl alcohol, benzylhemiformal, benzylparaben, 5-bromo-5-nitro-1,3-dioxane, 2-bromo-2-nitropropane-1,3-diol, butyl paraben, phenoxyethanol, methyl paraben, propyl paraben, diazolidinyl urea, calcium benzoate, calcium propionate, captan, chlorhexidine diacetate, chlorhexidine digluconate, chlorhexidine dihydrochloride, chloroacetamide, chlorobutanol, p-chloro-m-cresol, chlorophene, chlorothymol, chloroxylenol, m-cresol, o-cresol, DEDM Hydantoin, DEDM Hydantoin dilaurate, dehydroacetic acid, diazolidinyl urea, dibromopropamidine diisethionate, DMDM Hydantoin, and all of those disclosed on pages 570 to 571 of the CTFA Cosmetic Ingredient Handbook, Second Edition, 1992, which is hereby incorporated by reference.
[0243] J. Vitamins and Antioxidants
[0244] The compositions of the invention may contain vitamins and/or coenzymes, as well as antioxidants. If so, 0.001-10%, preferably 0.01-8%, more preferably 0.05-5% by weight of the total composition are suggested. Suitable vitamins include ascorbic acid and derivatives thereof, the B vitamins such as thiamine, riboflavin, pyridoxin, and so on, as well as coenzymes such as thiamine pyrophoshate, flavin adenin dinucleotide, folic acid, pyridoxal phosphate, tetrahydrofolic acid, and so on. Also Vitamin A and derivatives thereof are suitable. Examples are Vitamin A palmitate, acetate, or other esters thereof, as well as Vitamin A in the form of beta carotene. Also suitable is Vitamin E and derivatives thereof such as Vitamin E acetate, nicotinate, or other esters thereof. In addition, Vitamins D and K are suitable.
[0245] Suitable antioxidants are ingredients which assist in preventing or retarding spoilage. Examples of antioxidants suitable for use in the compositions of the invention are potassium sulfite, sodium bisulfite, sodium erythrobate, sodium metabisulfite, sodium sulfite, propyl gallate, cysteine hydrochloride, butylated hydroxytoluene, butylated hydroxyanisole, and so on.
[0246] III. The Compositions
[0247] The cosmetically acceptable carrier for the Acetyl Hexapeptide-3 may be a wide variety of cosmetic compositions including but not limited to creams, lotions, gels, and colored cosmetic compositions such as foundation, lipstick, eyeshadow, blush, concealer, eyeliner, mascara, nail enamel, and the like. Typical ranges of ingredients found in such compositions include, but are not limited to, those set forth herein.
[0248] Creams and lotions generally comprise from about 0.1-99% water, 0.1-99% oil, about 0.001-20% of one or more surfactants, and may optionally include any one or more of the ingredients set forth in Section II above. Creams have a more viscous consistency while lotions tend to be less viscous, or more pourable.
[0249] Typical foundation makeup compositions and concealers may be found in the emulsion form and will generally comprise from about 0.1-99% water, 0.1-99% oil, about 0.001-20% of one or more surfactants, and from about 0.01-30% of particulate material which may be pigments, powders, or mixtures thereof. The foundation makeup composition may optionally comprise any of the other ingredients described in Section II above, and in the ranges set forth.
[0250] Foundation makeup, powder, and concealer compositions may also be in the anhydrous form. If so, typical ranges of ingredients include from about 0.1-75% oil and about 0.1-75% particulate materials, which may be pigments, powders, or mixtures thereof. Such compositions may optionally contain one or more of the ingredients set forth in Section II and in the ranges set forth.
[0251] Blushes and eyeshadows may be in the water and emulsion form, and if so, typically contain the ranges of ingredients set forth above with respect to foundation makeup and, optionally, any one or more of the other ingredients set forth in Section II, and in the same amounts. However, blushes and eyeshadows may also be in the anhydrous form and, if so, contain the ranges of ingredients set forth with respect to the anhydrous foundation and powder compositions mentioned above and the optional ingredients listed in Section II, above.
[0252] Typically, lipsticks contain from about 0.01-99% oil, 0.1-50% structuring agent, and from about 0. 1-50% of particulates which may be pigments, powders, or mixtures thereof. The lipsticks may contain one or more of the ingredients mentioned in Section II and in the same ranges as set forth therein.
[0253] Mascara compositions may be in the emulsion form, and if so, typically contain from about 0.1-99% water and from about 0.1-99% oil, and 0.1-50% particulate matter. Optionally, mascaras may contain from about 0.1-50% surfactants, and the other ingredients set forth in Section II above. Mascaras may also be anhydrous, and if so, may comprise from about 0.1-99% oil, 0.1-50% particulate matter, and, optionally, one or more of the ingredients set forth in Section II and in the ranges set forth.
[0254] In general, the Acetyl Hexapeptide-3 may be incorporated into any type of cosmetic composition.
[0255] The invention will be further described in connection with the following examples which are set forth for the purposes of illustration only.
EXAMPLE 1
[0256] An oil-in-water emulsion facial and body cream with SPF was prepared as follows:
INGREDIENT w/w % Butylene glycol 5.0 Preservatives 1.73 Magnesium Ascorbyl Phosphate 0.01 Silica 0.75 Glycerin 5.0 Talc 0.75 Carbomer (2.5% aqueous solution) 20.0 Octyl methoxycinnamate 7.5 Octyl salicylate 3.0 Homosalate 5.0 Benzophenone-3 (Oxybenzone) 2.0 4-tert-butyl methoxydibenzoylmethane (Avobenzone) 2.0 Dimethicone 2.0 Cetyl Alcohol 1.5 Stearyl Alcohol 0.75 Talc 0.75 PPG-2 Myristyl Ether Propionate 4.5 C12-15 Alkyl Benzoate 1.0 Tocopheryl Acetate 0.1 Aloe Barbadensis Leaf Extract 0.1 Retinyl Palmitate 0.01 Lauryl Lactate 1.5 Butylene Glycol Dicaprylate/Dicaprate 5.0 Peg 100 Stearate 0.75 Polysorbate 60 2.6 Sorbitan stearate 0.9 Triethanolamine 1.0 Mica, Titanium 1.0 Glycyrrhia Glabra extract in cyclomethicone 1.0 Salix Nigra (willowbark) Extract 1.0 Oleyl alcohol, Dioscorea Villosa (Yam) Root Extract, Glycine 1.0 Sojo (soybean) sterols Trifolium Pratense (Clover) Flower Extract, glycerin, butylene 1.0 glycol, lecithin Water, glycerin, Macrocystis Pyrifera Extract, hydrolyzed wheat 1.0 protein PEG-40 hydrogenated castor oil, Pyrus Malus 0.5 (apple) Fruit extract Saxifraga Sarmentosa Extract, Vitis Vinifera (grape) 0.5 Fruit Extract, butylene glycol, Morus Bombycis (Mulberry) Root extract, Scutellaria Baicalensis Root extract, disodium EDTA, water Methoxypropylgluconamide 0.3 Sodium hydroxide 0.050 Acetyl Hexapeptide-3 1.00 Anthemis Nobilis Flower Extract (chamomile Roman), Salvia 0.3 Sclarea (clary) extract, citrus medica limonum (lemon) peel extract Water QS
[0257] The composition was prepared by heating water, glycols, preservatives, magnesium ascorbyl phosphate, silica, glycerin and talc to 80° C. with sweep mixing.
[0258] Once uniform, the carbomer solution was added with sweep agitation maintaining a temperature of 80° C. In a separate vessel oil phase ingredients (Octyl methoxycinnamate to Sorbitan stearate) were mixed with propeller agitation and heated to 80° C. Once both phases reached 80° C. the oil phase was transferred into the water phase with fast agitation. Once the transfer was completed the composition was neutralized with triethanolamine, followed by addition of the mica and titanium dioxide. The mixture was homogenized for 15 minutes, then cooled to 50° C. with continuous agitation. Once the bulk was cooled to 50° C. the remaining ingredients were added with mixing. The sodium hydroxide and N-Acetyl Hexapeptide-3 were premixed with water (1%) in a container before adding to the mixture. The mixture was then cooled to 30° C. and poured into suitable containers.
EXAMPLE 2
[0259] An oil-in-water emulsion face and body moisturizing cream was prepared as follows:
INGREDIENT w/w % Preservatives 0.65 Beeswax 1.25 Hydrogenated polyisobutene 5.00 Sorbitan stearate 3.00 Hydrogenated coco-glycerides 1.00 Octyldodecanol 2.00 Cetearyl ethylhexanoate 3.00 Capric caprylic triglycerides 3.00 Glyceryl stearate 2.00 Cetearyl alcohol, ceteareth-20 3.00 Stearic acid 3.15 Tetradibutyl Pentaeryrityl hydroxyhydrocinnamate 0.05 Glycerrhiza Glabra (licorice) Extract in cyclomethicone 1.00 Cyclomethicone 1.00 Triethanolamine 0.79 Phenoxyethanol 1.00 Oleyl alcohol, Dioscorea Villosa (wild yam) Root Extract, 1.00 Glycine Soja (soybean) sterols Acetyl Hexapeptide-3 Water QS
[0260] The cream was prepared by heating the water, preservatives, and magnesium ascorbyl phosphate, glycerin and glycols to 80° C. with sweep mixing. Once uniform, the carbomer solution was added with sweep agitation maintaining the temperature at 80° C. In a separate vessel the oil phase ingredients (dimethicone through glyceryl stearate, PEG 100 stearate in the above formula) were mixed with propeller agitation and heated to 80° C. Once both phases reached 80° C. the oil phase was transferred into the water phase with fast agitation. Once transfer was completed the mixture was neutralized with triethanolamine, followed by homogenization for 15 minutes. The mixture was cooled to 60° C. with continuous agitation, after which the water and sclerotium gum mixture was added to the mixture and further homogenized for an additional 15 minutes. Then bulk was then cooled to 50° C. and glyceryl polyacrylate, dimethiconol, and cyclomethicone were added to the batch, followed by further homogenization for 15 minutes. Then the remaining ingredients were added with mixing. Sodium hydroxide, kinetin, and water (1%) were premixed in a container, then added to the mixture. The mixture was then cooled to 30° C. and poured into suitable containers.
EXAMPLE 3
[0261] A liquid foundation makeup formula was prepared as follows:
INGREDIENT w/w % Water QS Glycerin 1.00 Butylene glycol 1.00 Cellulose gum 0.10 Magnesium aluminum silicate 0.20 Triethanolamine 1.30 Trisodium EDTA 0.05 Sorbitan sesquioleate 0.20 PEG-30 glyceryl cocoate 1.00 Oleth-3 phosphate 0.10 Ceteth-10 0.50 Lecithin treated red iron oxide/talc 0.38 Lecithin treated iron oxides 0.94 Lecithin treated titanium dioxide 3.00 Lecithin treated talc 3.97 Mica, iron oxides, soy amino acids, acacia dealbata wax 0.20 Nylon-12 3.00 Talc, soy amino acids, acacia dealbata wax 3.50 Micropulverized titanium dioxide 1.00 Titanium dioxide 4.00 Butylene glycol 1.50 Xanthan gum 0.15 Meadowfoam seed oil 2.00 Dimethicone 10.00 Isostearic acid 3.50 Propylene glycol dicaprylate/dicaprate 5.60 Isocetyl stearate 3.40 Phenyl trimethicone 1.85 Octinoxate 3.50 Glyceryl stearate/sodium lauryl sulfate 0.50 Propyl paraben 0.10 Steareth-2 0.75 Zinc oxide/dimethicone 0.20 Glycerin 2.00 Butylene glycol 2.50 Talc, lecithin 0.01 Methyl paraben 0.25 Tocopherol 0.40 Retinyl palmitate 0.08 Methyldihydrojasmonate 0.20 Pectin 0.05 Methoxypropylgluconamide 0.50 Hydrolyzed wheat protein 0.10 Hydrolyzed glycosaminoglycans 2.00 Sodium hyaluronate, hydrolyzed glycosaminoglycans 0.10 N-Acetyl Hexapeptide-3 1.00 Green tea glycospheres 0.20 Imidazolidinyl urea 0.20
[0262] The composition was prepared by combining the oil and water phase ingredients separately and emulsifying to mix.
EXAMPLE 4
[0263] An anhydrous foundation makeup was prepared as follows:
INGREDIENT w/w % Cyclomethicone 18.21 Dimethicone 13.31 Propyl parraben/laureth-7 (33%) 1.70 Boron nitride 1.63 Iron oxides, methicone 2.76 Titanium dioxide, alumina, methicone 4.76 Titanium dioxide, cyclomethicone, PEG/PPG-18/18/ 27.21 dimethicone, polyglyceryl-6-ricinoleate, stearic acid, aluminum hydroxide Zinc oxide, cyclomethicone, PEG-10 dimethicone, dimethicone 11.34 Titanium dioxide, cylcomethicone, dimethicone copolyol, 8.62 triethoxycaprylylsilane Mica, methicone 5.22 Silica 0.34 Nylon-12 2.34 Boron nitride 1.56 Acetyl Hexapeptide-3 1.00
[0264] The composition was prepared by combining the ingredients and mixing well.
EXAMPLE 5
[0265] Various cosmetic formulations were made according to the following formulas:
1 (pressed 2 (face 3 (con- Ingredient powder) powder) cealer) Boron nitride 20.00 5.00 3.00 Silica 0.50 5.28 Silica, sodium hyaluronate 0.50 0.50 — Methoxypropylgluconamide 0.10 0.10 0.10 Methylparaben 0.20 0.20 0.10 Diazolidinyl urea 0.10 0.10 — Propyl paraben 0.10 0.10 — Ethyl paraben 0.15 0.15 — Bismuth oxychloride 15.00 5.00 — Polyethylene 11.00 3.00 — Zinc stearate 9.00 5.00 — Talc, methicone, mineral oil 24.35 — — Mica, iron oxides, soy amino acids, 0.20 0.02 0.20 acacia dealbata flower wax Mica, methicone, mineral oil 10.00 15.00 — Titanium dioxide, isopropyl titanium 2.95 — 3.50 triisostearate Hydrogenated olive oil 0.10 — — Dimethicone QS — 7.84 Acetyl hexapeptide-3 0.25 0.25 0.25 Water, gingko biloba extract, 0.25 0.25 — ginseng root extract, camellia sinensis leaf extract, centaurea cyanus flower extract, vitis vinefer (grape) seed extract Dimethicone, dimethiconol 1.70 — — Talc, methicone, mineral oil 0.10 — — Talc, lecithin — QS 1.435 Mica, barium sulfate, titanium dioxide — 1.00 0.44 Iron oxides, isopropyl titanium — 4.14 — triisostearate Nylon-12 — 10.00 1.00 Talc, soy amino acids, acacia — 8.00 2.54 dealbata wax Lauroyl lysine — 6.00 2.20 Aloe barbadensis leaf extract — 0.10 0.10 Dimethicone, trimethylsiloxysilicate — 3.00 0.25 Coco caprylate/caprate — 2.00 — Phenyl trimethicone — 1.50 — Hydrogenated olive oil — 0.80 — unsaponifiables, black currant fruit extract Tocopheryl acetate — 0.10 0.02 Tocopherol — 0.10 — Tridecyl trimellitate — — 2.15 Neopentyl glycol Diethylhexanoate — — 6.15 Sorbitan trioleate — — 0.50 Pentahydrosqualene — — 0.50 Isopropyl isostearate — — 9.67 Cyclomethicone, trimethylsiloxysilicate — — 5.00 BHT — — 0.10 Myristyl myristate — — 1.40 Candelilla wax — — 0.96 Tribehenin — — 6.30 Hydrogenated coco-glycerides — — 1.86 Saxifraga sarmentosa extract, — — 0.02 vitis vinefera fruit extract, butylene glycol, water, morus bombycis root extract, scutellaria baicalensis root extract, disodium EDTA Salicylic acid, hydrolyzed vegetable — — 0.02 protein Titanium dioxide, aluminum hydroxide, — — 22.00 stearic acid, dimethicone, isopropyl isostearate Zinc oxide, dimethicone, isopropyl — — 4.00 isostearate Bismuth oxychloride — — 2.00 Titanium dioxide — — 2.00 Trimethylsiloxy silicate, — — 4.07 cyclomethicone, iron oxides Preservatives — — 1.40 Retinyl palmitate — — 0.02 Lauryl PEG/PPG-18/18 methicone — — 0.50 Magnesium ascorbyl phosphate — — 0.02 Polyglyceryl-4-isostearate — — 1.00
[0266] The compositions were prepared by combining the ingredients and mixing well.
[0267] Unless otherwise noted, all $ values given herein are by weight % (i.e., wt. %).
[0268] A number of references have been cited, the entire disclosure of which are incorporated herein by reference.
[0269] While the invention has been described in connection with the preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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A cosmetic composition comprising Acetyl Hexapeptide-3 in a cosmetically acceptable carrier, and use of such cosmetic compositions in improving skin conditions associated with aging such as wrinkles, fine lines, laxity, mottled pigmentation, and sallowness.
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The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of grant number CA25874 awarded by the National Institutes of Health.
This application is a continuation of application Ser. No. 149,100 filed Jan. 27, 1988 now abandoned.
TECHNICAL FIELD OF THE INVENTION
The invention is in the field of cancer therapy. More particularly the invention relates to anti-tumor antibodies.
BACKGROUND OF THE INVENTION
Epidermal growth factor (EGF) is a polypeptide hormone which is mitogenic for epidermal and epithelial cells. When EGF interacts with sensitive cells, it binds to membrane receptors; the receptor EGF complexes cluster and then are internalized in endocytotic vesicles. This is responsible for the phenomenon of "down-regulation". EGF binding induces a tyrosine kinase activity of the receptor molecule and induces synthesis of DNA.
The EGF-receptor is a transmembrane glycoprotein of about 170,000 Daltons. (Cohen, J. Biol. Chem., Vol. 258, pp. 1523-1531, 1982.) It is the gene product of the c-erb-B proto-oncogene. (Downward, et al., Nature, Vol. 307, pp. 521-527, 1984.) The receptor exists in two kinetic forms: so-called, low affinity and high-affinity receptors. These may be interconvertible. (Fernandez-Pol, Biol. Chem., Vol. 260, pp. 5003-5011, 1985.)
The A431 carcinoma cell line expresses abundant EGF-receptors on its cell surfaces, and thus has been used in many studies to generate anti-EGF-receptor antibodies. However, the receptors on A431 differ from those of other cell types in the carbohydrate moieties attached to the polypeptide. Thus many antibodies raised against A431 membranes are directed against carbohydrates which are not common to all forms of the receptor molecule. (See, for example, Richert, Fed. Proc., Vol. 42, p. 1094, 1983, Schreiber, J. Biol. Chem., Vol. 258, pp. 846-853, 1983, Gooi, Bioscience Reports, Vol. 3, pp. 1045-1052, 1983, Vol. 5, pp. 83-94, 1985 and Molecular Immunology, Vol. 22, pp. 689-693, 1985.)
Others have generated monoclonal antibodies which are reactive with the protein moiety of EGF-receptors. These antibodies display a variety of properties upon binding to EGF-receptors, presumably dependent on the particular portion of the receptor molecule bound, and the isotype of the antibody. Some antibodies mimic some of the effects of EGF (agonists) and some inhibit the effects (antagonists).
Expression of EGF-receptors has been implicated in the progression of tumor growth. The gene for the receptors has been found to be the cellular analogue of the arian vital oncogene v-erb-B. (Ullrich, et al, Nature, Vol. 309, pp. 418-425, 1984.) In addition, an association has been detected between late stages of melanoma development and extra copies of the chromosome carrying the receptor gene. (Koprowski, et al., Somatic Cell and Molecular Genetics, Vol. 11, pp. 297-302, 1985.)
Because EGF receptors are expressed on a wide variety of solid tumors they provide a suitable target for anti-tumor therapy. However, there is a need in the art for a suitable anti-receptor antibody. Many of the known antibodies have properties which would be deleterious if used as anti-tumor agents. For example, antibodies which mimic the effects of EGF could stimulate the progression of the tumor rather than arresting it. Other antibodies which only bind to high or low affinity receptors could be less than optimally effective because EGF could still exert its effect through the unbound receptors. Still other antibodies convert low affinity receptors to high affinity receptors, which could exacerbate tumor growth rather than inhibiting it. Thus there is a need in the art for an anti-EGF-receptor antibody which would be suitable for anti-tumor therapy.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a monoclonal antibody which binds to receptors for EGF and inhibits both high and low affinity binding of EGF.
It is another object of the invention to provide an antibody which inhibits the effects of EGF on sensitive cells.
It is yet another object of the invention to provide an antibody which inhibits phosphorylation of the EGF receptor.
It is still another object of the present invention to provide a method of treating human patients having solid tumors with anti-EGF receptor antibodies.
It is still another object of the invention to provide a method of treating human patients having solid tumors with lymphokines and anti-EGF receptor antibodies.
It is yet another object of the invention to provide a diagnostic method for solid tumors using antibodies raised against EGF-receptors.
These and other objects of the invention are provided through one or more of the following embodiments. In one embodiment, a monoclonal antibody is provided which has the following properties: (a) binds to human EGF-receptors; (b) inhibits both low and high affinity binding of EGF to EGF-receptors; (c) inhibits the EGF-dependent tyrosine kinase activity of EGF-receptors; (d) inhibits the growth of EGF-sensitive cells at a concentration of greater than 1 nM.
In another embodiment a cell line which produces the anti-EGF-receptor antibody is provided.
In still another embodiment a method is provided wherein patients with solid tumors are treated to arrest tumor growth. The method comprises the step of administering monoclonal antibodies to the patients. The antibodies have the ability to bind to the EGF receptor, to inhibit both low and high affinity binding of EGF to the receptors, to inhibit the tyrosine kinase activity of EGF receptors, and to inhibit the growth of EGF-sensitive cells at a concentration greater than 1 nM.
In yet another embodiment a method is provided where a lymphokine preparation is administered to a patient to induce enhanced expression of EGF-receptors on the surface of tumor cells, in conjunction with monoclonal anti-EGF receptor antibody administration.
In still another embodiment of the present invention a diagnostic method is provided in which radiolabelled F(ab') 2 fragments are prepared from the monoclonal antibodies of the present invention, and administered to patients. The location and size of the tumor are determined by gamma-scintigraphy to detect the radiolabelled F(a') 2 fragments.
The methods and antibodies of the present invention provide the art with a new and potent anti-tumor therapy. It is applicable to a wide range of solid tumors and avoids the need for radioisotopes. The latter benefit is especially desirable in the treatment of children. The antibodies can also be used in a radiolabelled form, both therapeutically and diagnostically.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the inhibitory effect of 425 antibody on autophosphorylation of EGF-receptor.
FIGS. 2A-C show the inhibiting effect of 425 antibody on EGF- induced DNA synthesis in quiescent (A) human foreskin, (B) human WI-38, and (C) murine 3T3 fibroblastic cells.
FIGS. 3A and 3B depict the 425 antibody-induced down-regulation of the EGF receptor in human (A) colorectal and (B) epidermoid carcinoma fibroblastic cells.
FIG. 4 depicts the effect of 425 antibody on the binding of EGF to A431 membranes.
FIG. 5 depicts the effect of lymphokine preparations on the expression of EGF-receptors in SW116 colorectal carcinoma cells.
FIG. 6 depicts 425 antibody binding to A431 membranes.
FIGS. 7A and 7B shows the effect of antibody 425 on growth of human (A) colorectal and (B) epidermoid carcinoma tumors on nude mice.
DETAILED DESCRIPTION
The present invention provides a monoclonal antibody which immunoprecipitates EGF-receptors. This binding interaction between the antibody and antigen occurs both in the presence and in the absence of the hormone EGF, suggesting that the binding of antibody occurs in a site distinct from the hormone binding site of the receptor. However, the antibody binding site is probably close to the hormone binding site, as the antibody inhibits binding of the hormone to the receptor.
Two populations of EGF-receptors have been defined, based on their binding affinities for hormone: so-called high and low affinity receptors. The antibodies of the present invention bind to both types of receptors and inhibit hormone binding to both types of receptors. It has been suggested that the high affinity receptors are the population responsible for mediating the mitogenic response of cells to EGF. (Kawamoto, Proc. Nat'l. Acad. Sci. U.S.A., vol. 80, pp. 1337-1341, 1983.) Thus the ability of the antibody of the present invention to bind and inhibit those receptors could be the basis of their cytostatic effect.
The antibodies of the present invention inhibit the EGF-induced synthesis of DNA in quiescent human fibroblasts. No such inhibition is seen on murine fibroblasts. Thus the antibodies provided are apparently species specific.
The antibodies of the invention inhibit EGF-induced autophosphorylation of the EGF receptor. In the absence of EGF there is a basal level of phosphorylation which the antibodies do not effect appreciably. However, the phosphorylation which is induced by EGF is dramatically reduced by the antibody. For example, preincubation of receptors with 10 nM antibody, reduced the amount of autophosphorylation induced by 200 nM EGF by about 70%.
The binding site of antibodies of the invention on the receptor has been localized to one of the three trypsin generated fragments. The three fragments produced by limited trypsin proteolysis are about 17, 42, and 100 KDa and correspond to the autophosphorylation locus, the tyrosine kinase domain, and the hormone binding domain, respectively. The largest fragment is specifically immunoprecipitated by the antibodies of the invention. The antibody also binds to a 100 KDa form of the receptor which is secreted by A431 cells as the product of a truncated gene. This short and soluble receptor binds hormone but has no kinase site. (Weber et al, Science, Vol. 224, pp. 294,298, 1984).
Analysis of binding of the antibodies to A431 membranes indicates that there are two binding components, one high-affinity and one low-affinity. There are about 40-fold fewer of the high-affinity sites than the low-affinity sites, but their binding affinity is about 10,000-fold higher. The antibodies do not change the affinity of the receptors for EGF, but do reduce the number available for binding.
Antibodies of the above description can be produced using cell line 425 deposited at the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md., 20852 as Accession No. HB 9629 on Jan. 26, 1988. Growth of the cell line in vitro, using standard methods, produces a culture supernatant containing the appropriate antibodies. Alternatively the cells can be grown in vivo in nude mice and the ascites fluid collected. Both methods are well known to those of ordinary skill in the art.
The antibodies can be administered to human patients for therapy or diagnosis according to known procedures. Typically the antibody, or antibody fragments, will be injected parenterally, preferably intraperitoneally. However, the monoclonal antibodies of the invention can also be administered intravenously. In some cases immunosuppression of the patient may be desirable to minimize any adverse reaction toward the injected antibodies.
Determination of appropriate titers of antibody to administer is well within the skill of the art. Generally, the dosage ranges for the administration of the monoclonal antibodies of the invention are those large enough to produce the desired tumor suppressing effect. The dosage should not be so large as to cause adverse side effects, such as unwanted cross-reactions, anaphylactic reactions, and the like. Generally, the dosage will vary with the age, condition, sex and extent of the disease in the patient and can be determined by one of skill in the art. The dosage can be adjusted by the individual physician in the event of any counter indications, immune tolerance or similar conditions. Dosage can vary from 0.1 mg/kg to 70 mg/kg, preferably 0.1 mg/kg to 500 mg/kg/dose, in one or more doses administrations daily, for one or several days.
Preparations for parenteral administration includes sterile aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's, or fixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers, such as those based on Ringer's dextrose, and the like. Preservatives and other additives may also be present such as for example, antimicrobials, antioxidants, chelating agents, and inert gases and the like.
For diagnostic purposes the antibody can be conjugated to a radio-opaque dye or can be radiolabelled. A preferred labelling method is the Iodogen method. Fraker et al, Blochem. Biophys. Res. Commun., Vol. 80, p. 849-857, 1978. Preferably the antibody will be administered as F(ab') 2 fragments for diagnostic purposes. This provides superior results so that background subtraction is unnecessary. Fragments can be prepared by known methods. See, e.g., Herlyn et al, Cancer Research, Vol. 43, pp. 2731-35, 1983. Generally, pepsin digestion is performed at acid pH and the fragments are separated from undigested IgG and heavy chain fragments by Protein A- Sepharose™ chromatography.
For therapeutic purposes the antibody can be conjugated to a toxin such as ricin subunit A, diptheria toxin, or a toxic enzyme. Alternatively it can be radiolabelled according to known methods in the art. However, the antibody of the present invention displays excellent cytotoxicity, in the absence of toxin, in the presence of effector cells, i.e. human monocytes.
Solid tumors which can be detected and treated using the present methods include melanoma, glioma and carcinoma. Cancer cells which do not highly express EGF-receptors can be induced to do so using lymphokine preparations. Also lymphokine preparations may cause a more homogeneous expression of EGF receptors among cells of a tumor, leading to more effective therapy.
Lymphokine preparations suitable for administration include interferon-gamma, tumor necrosis factor, and combinations thereof. These can be administered intravenously. Suitable dosages of lymphokine are 10,000 to 1,000,000 units/patient.
The following examples illustrate the general principles of the invention, but do not limit its scope.
EXAMPLE 1
This example illustrates the production of monoclonal antibody.
A Balb/c mouse was injected intraperitoneally with 2×10 7 A431 cells and phosphate-buffered saline (PBS). Twenty-five days later the mouse was reinjected intravenously with 2×10 6 A431 cells and PBS. On the third day following the second injection, the spleen was removed and the cells were fused with P3×63Ag8.653 mouse myeloma cells. (See, Kohler et al, Nature, Vol. 256, pp. 495-497, 1975; and Koprowski et al, Somatic Cell Genetics, Vol. 5, pp. 957-972, 1979.) The fusion products were grown in Dulbecco's modified Eagle's (DME) medium containing 20% fetal bovine serum (FBS) and hypoxanthine/aminopterin/thymidine.
The hybridoma supernates were screened for binding to A431 cells using a mixed hemeadsorption assay. (Herlyn, et al, Proceedings of the National Academy of Sciences U.S.A., Vol. 76, pp. 1438-1442, 1979.) Supernates from positive clones were tested for inhibition of 125 I-EGF binding to A431 cells. Hybrids whose supernates inhibited EGF binding were cloned twice and then maintained in the above medium. The antibody (No. 425) was purified from ascitic fluid produced in Balb/c mice using Protein A-Sepharose columns. It was established that the antibody class was IgG 2a by indirect radioimmunoassay. (Herlyn et al, Cancer Research, Vol. 45, pp. 5670-76, 1985.)
EXAMPLE 2
This example demonstrates the inhibitory effect of 425 antibody on kinase activity of the EGF receptor as measured by autophosphorylation.
Solubilized receptor (about 30 ng, based on EGF binding ability) was subjected to the following successive treatments; (a) incubation at 4° C. for 60 minutes with or without 425 antibody in 15 ul of 20 mM Hepes, 10% glycerol, pH 7.4, 0.2% Triton X-100; (b) incubation at 4° C. for 10 minutes with or without 1 ul of 15 uM EGF. Phosphorylation was initiated by the addition of 5 ul of a solution containing 60 uM gamma- 32 P-ATP (100 cpm/fmol) and 4 mM MnCl 2 . After incubation at 4° C. for 30 minutes the reactions were terminated and the samples were subjected to SDS-polyacrylamide gel electrophoresis and autoradiography.
The extent of receptor phosporylation was quantified by measuring the radioactivity in the region of the dried gel containing the receptor band. Dried gel strips of similar dimensions from adjacent regions were counted to correct for background radioactivity. The results are shown in FIG. 1. The EGF-induced kinase activity of the solubilizied human receptor, measured as the extent of autophosphorylation, was blocked by the antibody.
EXAMPLE 3
The example shows the inhibitory effect of antibody 425 on EGF-induced DNA synthesis in quiescent fibroblastic cells.
Human foreskin fibroblasts, human WI-38 fibroblasts, and murine 3T3 fibroblasts were tested. Cells were plated in 16-mm dishes at a denisty of 10 5 cells per well in 1 ml of DME medium contain 10% FBS. After 24 hours at 37° C. the medium was replaced with 1 ml of DME medium containing 1% platelet-poor plasma. After 5 days at 37° C. these cells were preincubated with 425 antibody at 24° C. for 30 minutes in 0.3 ml of DME-medium containing 1% FBS. Then EGF was added and the monolayers were incubated at 37° C. At 18 hours after EGF addition, tritiated thymidine (1.5 Ci/mmol) was added to a final concentration of 1 uCi/ml and the incubations were continued at 37° C. for an additional 6 hours. Trichloroacetic acid insoluble radioactivity was determined. As can be seen in FIG. 2, the antibody was found to inhibit EGF-dependent DNA synthesis in both types of human fibroblastic cells, but not in the mouse 3T3 cell line.
EXAMPLE 4
This example demonstrates the phenomenon of down-regulation of the EGF receptor in human fibroblastic cells induced by the 425 antibody.
Human WI-38 fibroblasts and human foreskin fibroblasts were first incubated with antibody at 4° C. for a time long enough for binding equilibrium to be achieved, and then the cell dishes were transferred to 37° C. to allow endocytosis and down-regulation to occur. Subsequently, the dishes were washed extensively with antibody-free medium, and the extent of down-regulation (i.e., loss of surface receptor activity) was quantitated by determining EGF binding activity at 4° C. for 2 hours using a saturating concentration of 125 I-EGF.
Monolayers of cells in 35-mm dishes were incubated at 4° C. for 2 hours with 1 nM 425 antibody in 1 ml of DME medium containing 1 mg/ml BSA (DME-BSA). then the dishes were transferred to 37° C.; at the indicated times of incubation at 37° C., the dishes were transferred to ice, washed extensively with ice-cold DME-BSA and then incubated at 4° C. for 2 hours with 40 nM 125 I-EGF (10 6 cpm/pmol) in 1 ml of DME-BSA.
The results in FIG. 3 show the percentage of the control binding in cells at various times of 37° C. incubation with antibody. Control cells underwent identical treatment except for the absence of antibody. One hundred percent binding represents the specific binding of a 150 and 110 fmol 125 I-EGF to WI-38 and foreskin fibroblasts, respectively. Nonspecific binding was 4000 and 7500 cpm for WI-38 and foreskin fibroblasts, respectively.
EXAMPLE 5
This example depicts the effect of 425 antibody on the equilibrium binding of EGF to A431 membranes.
Isolated membranes were prepared according to the method of Biswas, Biochemistry, Vol. 24, pp. 3795-3802, 1985. The membranes were preincubated at 4° C. for 1 hour with or without 425 antibody. The membranes were then incubated at 20° C. for 1 hour with 125 I-EGF in 15 ul of 20 mM Hepes, pH 7.4/0.15M NaCl (Hepes/NaCl) containing 1 mg/ml BSA. At the end of the incubation 1 ml of ice-cold Hepes/NaCl was added, and the suspension was passed through Millipore™ EGWP 0.2-um pore filters. The filters are washed three times with Hepes/NaCl and assayed for radioactivity in a gamma-counter. Nonspecific binding was determined in the presence of 5 uM unlabeled EGF.
Scatchard analysis of EGF binding to A431 membranes shows that in the presence of antibody, there is a reduction in the number of both high and low affinity EGF binding sites. There is no alteration in the binding affinity. These results suggest that the antibody can bind to both high and low affinity EGF receptors. The binding of the antibody to the high-affinity receptors is of interest because these receptors may represent the mitogenically active entities.
EXAMPLE 6
This example shows the effect of lymphokine preparations on the expression of EGF receptors in SW 116 colorectal carcinmoa cells.
Expression of EGF receptors was tested with 125 I-labelled monoclonal antibody 425. The antibody was labelled by mixing 5 ug of purified antibody with carrier-free Na 125 I (0.5 mCi) in 0.1M potassium phosphate buffer, pH 7.5 (total volume 10 ul). 10 ul of chloramine T (2 mg/ml) were added and mixed for 1 minute at 24° C. The reaction was terminated by the addition of 10 ul of 4 mg/ml sodium metabisulfite (4 mg/ml) and 10 ul of KI (70 mg/ml). The labelled protein was separated from unreacted Na 125 I by gel filtration through Sephadex™ G-15. The buffer used for diultion contained 10 mM Tris-HCl pH 7.4, 0.15M NaCl, and 1 mg/ml bovine serum albumin. The specific radioactivity of the preparation was about 100,000 cpm/ng protein.
FIG. 5 shows the effect on cells which were cultured for 72 hours in the presence of various concentrations of interferon-gamma, tumor necrosis factor, or a combination of both. Results are expressed as cpm/10 3 cells.
EXAMPLE 7
This example depicts the 425 antibody binding to A431 membranes.
Membranes either were pretreated with EGF, or were left untreated, and then incubated at 20° C. for 1 hour with radioiodinated 425 antibody in Hepes/NaCl containing 1 mg/ml BSA. Membrane-bound radioactivity was determined after filtration through Millipore™ filters as described above. Nonspecific binding was determined in the presence of 0.3 uM unlabelled antibody.
Binding of radioiodinated antibody to A431 membranes was specific and saturable, as can be seen in FIG. 6. Scatchard analysis revealed the presence of two binding components, a high-affinity, low-capacity component (K d about 10 pM; about 5×10 8 sites/ug membrane protein,) and a relatively low-affinity, high-capacity component (K d about 1 nM; about 2×10 10 sites/ug membrane protein). The estimated number of antibody binding sites in these membranes is roughly equal to the number of EGF binding sites. Also the concentration of labelled antibody required for half saturation of the binding sites of A431 membranes is the same as that needed for half-maximal inhibition of EGF binding to these membranes. These results reconfirm that the antibody binds only to the EGF receptor and to no other membrane molecule.
EXAMPLE 8
This example demonstrates the lysis of tumor cells by monoclonal antibody 425 in tissue culture in the presence of effector cells.
In antibody-dependent, cell-mediated, cytotoxicity assays using either human monocytes, lymphocytes or murine macrophages, antibody 425 mediated tumor cell lysis of two EGF-receptor positive cell lines SW 948 and A431. The results are shown below in Table 1.
______________________________________MAb 425-dependent cell-mediated cytotoxicity with human andmurine effector cellsNumber % of specific cytotoxicity.sup.bof binding Human MouseCell line sites/cell.sup.a monocytes lymphocytes macrophages______________________________________A 431 1 × 10.sup.6 49.7 30.4 57.2SW 948 5 × 10.sup.4 12.5 6.8 30.1______________________________________ .sup.a Number of binding sites determined by Scatchard analysis. .sup.b Results are expressed as mean % cytotoxicity of duplicate samples, which varied <10% and are corrected for unspecific cytotoxicity induced b MAbs not binding to target cells (antiinfluenza virusantibodies H24B5 and H3585-5); range of nonspecific cytotoxicity 2-19%.
A431 cells which show high receptor density, were lysed to a greater extent than SW 948 cells, by both human and mouse effector cells in the presence of monoclonal antibody 425. These results suggest that cells with more binding sites are destroyed more efficiently than those with fewer binding sites.
EXAMPLE 9
This example demonstrates the inhibition of tumor growth in nude mice by monoclonal antibody 425.
Nude mice was xenografted with either SW 948 or A431 cells by subcutaneous inoculation. SW 948 cells are colorectal carcinoma cells and A431 cells are human epidermoid carcinoma-derived cells. Antibody 425 or control anti-influenza virus monoclonal antibody were administered intraperitoneally, starting on the day of tumor inoculation and on days 1, 2, 3, 4, 7, 9, 11, 14, 16, and 18 thereafter. Tumor volumes were recorded once weekly for six weeks after inoculation. As shown in FIG. 7, tumor volumes of mice inoculated with SW 948 cells remained unchanged until day 28 after inoculation. From then on, tumor volumes increased but remained considerably smaller than those of control mice. In the mice xenografted with the A431 cells, tumor growth was completely inhibited during the observation period of 45 days.
In another set of experiments, one group of three nude mice was xenografted with 2×10 6 A431 cells received a single dose of 200 ug of antibody 425 at the time of tumor implantation. Another group of four mice received the first injection of 200 ug of monoclonal antibody 425 five days after implantation of 3×10 6 of A431 cells. Marked inhibition of tumor growth was observed in both groups of mice.
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Monoclonal antibody 425 having properties particularly beneficial for anti-tumor therapy has been raised. MAb 425 antibody binds to EGF-receptors and inhibits their bioactivities. The amount of binding of the antibody to cancer cells can be increased by treatment of the cells with lymphokine preparations. Radiolabeled MAb 425 is used for treatment of EGF receptor-expressing gliomas.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a single-wheel driving mechanism, in particular for single-wheel floor transport vehicles, which is comprised of a gearing housing with at least one gear stage, a flanged-on drive motor and a driven running wheel.
2. The Prior Art
single-wheel driving mechanisms of the type specified above are preferably employed for floor conveyor vehicles. It is important in connection with such mechanisms that they have small and narrow dimensions, and that the risk for the vehicle of tilting over is reduced by keeping the center of gravity of the vehicle as low as possible. The installation space has to be kept small, so that the possibilities for maneuvering the vehicle are enhanced. Not to be disregarded in this connection is the fact that the driving forces and loads, which range from 1 to 3 tons, that have to be transmitted to one single running wheel via the single-wheel driving mechanism, are quite high, and that to that extent, the housing and the required gear stage consequently have to be designed for such loads.
A single-wheel driving system is known, for example from German Patent No. DE-PS 31 33 027, in connection with which a pinion of a spur gear drive is arranged on the shaft of the electric motor in connection with a two-stage type of gearing. This, however, causes the pitch circle to be relatively large due to the material thickness required between the foot of the tooth and the receiving bore, which means that the reducing gear ratio is consequently limited. Furthermore, such a constructional measure requires high manufacturing expenditure. The downwardly-extending support for the shaft of the spur gear and the bevel-gear pinion is disposed at the level of the rim and tire of the running wheel, which means that it is not possible to keep the spacing of the shaft from the center of the gearing axis as small as desirable for obtaining a particularly small turning radius.
Furthermore, known designs of single-wheel drive mechanisms have the disadvantage that their installation and removal require increased labor expenditure in particular for later maintenance and service purposes, and that the construction of the housing has to satisfy increased requirements.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a single-wheel driving mechanism that has the smallest possible installation space and permits simplified installation and removal while high forces are transmitted at the same time.
For solving this problem, the running wheel is directly connected with a gear with torsional strength, and the gear is supported in a rotating manner on a support element that is coaxially disposed on the inside and stationary. Due to the fact that the running wheel is directly connected with a gear with torsional strength and mounted on a support element, the number of structural components used can be substantially reduced. This results in cost savings and permits a substantial simplification of the construction. When the gear is rotatably supported on a pivot of the housing, or on a journal of the shaft that is mounted with torsional strength and received in a passage (or breakthrough) in the housing, it is possible to dispense with a flanged shaft with bearing elements, and to use a single-component housing without any cover and screw connections due to the simplified of construction. Such a design comprises an extremely narrow type of construction.
Furthermore, such an embodiment comprises a larger bevel gear combined with the same structural size of the gearing, and therefore leads to a reinforcement of the gearing. Admitting the force directly into the running wheel via the bevel gear is particularly advantageous as well. The shaft journal, which is received in a passage of the housing, may be preferably used when higher loads are involved. Furthermore, the shaft journal, which is not rotating, reinforces the housing in the lower areas in a beneficial manner, whereby the occurring forces are immediately introduced into the housing via the shaft journal. In this connection, the bevel gear located on the driven side may comprise a pot-shaped attachment extending in the direction of the running wheel. Such an attachment is molded on, forming one piece with the bevel gear, so that it is directly connected with the running wheel, and the largest possible support area can be formed versus the pivot of the housing or shaft journal.
The transmission system is designed in the form of a two-stage gearing, and a first gear stage, which has the tooth system of a spur wheel, is associated with the drive motor, whereas a second gear stage having the tooth system of a bevel gear, is associated with the running wheel. The two gear stages are connected by a driving shaft that is supported in the housing. The running wheel is connected with torsional strength with the bevel gear on the driven side; and the rim of the running wheel and/or the bevel gear are supported versus the pivot of the housing or the shaft journal via bearing elements. In the embodiment of the single-wheel driving mechanism as defined by the invention, the running wheel, together with the bevel gear on the driven side, is directly supported on a component of the housing, specifically on a housing pivot or shaft journal. Suitable bearing elements such as, for example antifriction bearings are used in this connection. The driving shaft, which is supported in the housing, connects the first gear stage consisting of the spur gear tooth system with the bevel gear stage for driving the running wheel, within the proximity of the driving motor. Due to the housing pivot or shaft journal, no minimum thickness of the wall of the housing is required for the arising forces because such forces can be directly transmitted to the running wheel. Furthermore, due to the special way in which the running wheel is secured, it is possible to design the body of the wheel in a variable manner, and it is in particular possible to continue to use existing wheel bodies in the present novel construction.
Viewed overall, it is thus possible to obtain a reinforcement of the transmission system by the novel construction with no change or reduction in the structural size. Such a system, moreover, requires fewer structural components and thus leads to a reduction of the labor expenditure for the installation or removal of the driving system.
In such an embodiment of the invention, the support element is arranged axially in relation to the running wheel and is connected with the housing, for example screwed to the latter or designed in a way so as to form one single piece with the housing. Or, in the case of the shaft journal, the support element is pressed into a passage (or breakthrough), whereby the support element is designed for receiving two antifriction bearings, on which the bevel gear and, if necessary, the rim of the running wheel can be supported. Taking into account the dimensions and loads specified for a single-wheel driving mechanism with the smallest possible installation space and an optimal tooth system and support ratio, it is possible to manufacture the driving mechanism at favorable cost by virtue of the novel construction as defined by the invention.
A further advantage consists in that the smallest possible radius of pivot around the vertical axis of the single-wheel driving mechanism is achieved especially in connection with running wheels that offer no space for accommodating any other support for the driving shaft because of their relatively small outside diameters between the hub and the rim of the running wheel. Due to the fact that its two bearings each are arranged outside of the tooth system as a result of the relatively large spacing between the two bearings, in particular the support of the driving shaft is realized in this connection in a particularly favorable manner. Adjusting a good support profile and favorable clearance (or play) of the bearing of the bevel gear drive, which has a tooth system in the form of a spiral or circular arc, is simplified because both the spur wheel and the bevel gear pinion can be mounted on the driving shaft in a fixed manner. For the required adjustment of the axial position of the tooth system of the bevel gear pinion and bevel gear, it is necessary to associate shims with the bearing in a simple manner, whereby the spur gear may be connected with the driving shaft by means of a pressed fit.
In a special embodiment of the invention, a pump device is integrated in the pivot of the housing or shaft journal, the latter being provided with torsional strength. Such a pump device is comprised of an axially movable tappet and a pressure chamber with an inlet valve and an outlet valve. With the help of the integrated pump device, it is possible to pump transmission oil from the lower interior space of the housing upwards to the lubrication system for the upper bearing elements. The special advantage offered by such a system is that the housing of the gearing does not have to be completely filled with oil, so that, for example no excessive slip can develop, and the degree of efficiency of the transmission is thus enhanced. At the same time, the pump device assures that the upper elements of the gearing and also the bearing elements can be adequately lubricated. The tappet is disposed in this connection with one end in a groove with a wavelike deepening that is formed in the pot-shaped attachment of the bevel gear, whereby the tappet is pressed into the groove in a spring-loaded manner and put into an axial movement that results from the rotational motion. The opposite side of the tappet is sealed off against a pressure chamber and is used as a piston (or plunger) that is capable of pumping the oil present upwards via an inlet valve and an outlet valve.
For this purpose, a bore formed to serve as an oil channel is provided in the driving shaft. This bore feeds into the pressure chamber via the outlet valve, whereas the inlet valve is connected with the lower interior of the gearing. The bore ends above the driving shaft at a level assuring adequate lubrication of the upper bearing elements.
The stump of the driven shaft of the electric motor may be provided with a pinion tooth system or a pinion and drives the spur wheel of the high-speed shaft of the electric motor with a lower number of teeth. This provides the reduction ratio of the spur wheel drive with an optimal value, so that taking into account the total reduction of this two-stage single-wheel driving mechanism, the reduction ratio of the bevel gear drive needs to be selected only adequately small that a number of teeth greater than the limit number of teeth can be provided for the tooth system of the bevel gear pinion. In this way, a more robust design is obtained in view of the high torque, as compared to driving mechanisms of this type equipped with spur gear pinions with a higher number of teeth.
The torque is thus transmitted with a pinion tooth system from the drive motor to the spur wheel. The spur wheel is connected with torsional strength with a driving shaft, whereby the driving shaft drives the bevel gear, the latter being connected with the running wheel, via a tooth system of the bevel pinion.
The housing is preferably designed in the form of one single component and comprises a first opening leading to the drive motor, and a second opening leading to the running wheel. These openings of the housing facilitate the installation and removal of the single-wheel driving mechanism. The first opening is closed after the installation by means of a screw connection with the inside ring of the bearing of the rotating ring, and the second opening is closed by the bevel gear and a clipped-in covering flap. Two sealing means are employed in this connection between the non-rotating and rotating elements, which limit the enclosed volume and prevent the transmission oil from leaking out.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 is a cut side view of a single-wheel driving mechanism as defined by the invention, comprising a pivot of the housing;
FIG. 2 is a cut side view of a single-wheel driving mechanism as defined by the invention, with a pressed-in shaft journal; and
FIG. 3 is a cut side view of a single-wheel driving mechanism as defined by the invention, comprising a pivot of the housing and an integrated pump device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the drawings, FIG. 1 shows a cut side view of a single-wheel driving mechanism 1 comprised of a drive motor 2 , a housing 3 with a two-stage gearing 4 , and a rotating rim bearing 5 for supporting the housing 3 in a pivoting manner.
Outer ring 6 of bearing 5 of the rotating rim is provided for the purpose of mounting the single-wheel driving mechanism 1 in a vehicle, whereby a plurality of the threaded bores 7 distributed over the circumference may be used for the screw connections. Inner ring 8 of the bearing of the rotating rim bearing receives a vertically mounted drive motor 2 and housing 3 , which is located underneath drive motor 2 . Thus drive motor 2 , together with housing 3 , can be swiveled vis-à-vis the floor transport vehicle to be driven. For driving the floor transport vehicle, provision is made for a running wheel 9 , which is mounted by pressing it onto a rim 10 of the running wheel. Running wheel 9 may consist of, for example a solid rubber or plastic wheel. According to the invention, rim 10 of the running wheel is screwed to the gear stage with a bevel gear 11 on the driven side by means of a plurality of the screw bolts 12 , which are distributed over the circumference. Rim 10 of the running wheel and bevel gear 11 rest on a pivot 13 of housing 3 , said pivot being shaped by molding on housing 3 , forming one piece with housing 3 . On its outer surface 14 , pivot 13 of housing 3 comprises two antifriction bearings 15 and 16 , which are directed against one another and supported by a contact pressure-exerting disk 17 . Contact pressure-applying disk 17 is screwed to pivot 13 of housing 3 by means of a screw bolt 18 . The antifriction bearings 15 and 16 , as well as screw bolt 18 are protected against soiling by a clamped-in (or clipped-in) cover cap 19 . Cover cap 19 closes opening 20 of housing 3 .
With its bevel gear tooth system 21 , bevel gear 11 mates with bevel pinion tooth system 22 of a bevel pinion 29 of driving shaft 24 . Driving shaft 24 is arranged with lateral offset versus drive motor 2 and supported vis-à-vis housing 3 by the upper and the lower antifriction bearings 25 , 26 . Antifriction bearings 25 and 26 each are mounted at the end side on driving shaft 24 and rest in the recesses 27 and 28 , respectively, of the housing 3 . The lower gear stage is formed by bevel gear 11 and a bevel pinion 29 secured on driving shaft 24 . Alternatively, it is possible to provide driving shaft 24 with a bevel tooth system.
The second gear stage is formed by a spur gear 30 with a spur gear tooth system 31 and a pinion tooth system 32 of electric motor shaft 33 . Electric motor shaft 33 protrudes beyond rotating rim bearing 5 into gear housing 3 , so that pinion tooth system 32 leads to engagement with spur gear tooth system 31 of spur gear 30 . Housing 3 is screwed to inner ring 8 of the rotating rim bearing via a plurality of the screw bolts 34 , which are distributed over the circumference. Recess 28 for receiving the upper antifriction bearing 26 of driving shaft 24 is closed by a sealed closing cap 35 . Inner ring 8 of the bearing of the rotating rim thus closes the upper opening of the housing 3 with the drive motor 2 , which is arranged vertically in relation to the transmission 4 . For avoiding soiling, outer ring 6 of the bearing of the rotating rim and inner ring 8 of the bearing of the rotating rim are sealed by seals 36 . Transmission 4 is sealed against dirt or oil loss by sealing elements 37 and 38 .
Drive motor 2 is mounted vertically on bearing 5 of the rotating rim and is screwed to inner ring 8 of the rotating rim by a plurality of screw bolts 40 , which are distributed over the circumference. Electric motor shaft 33 with armature winding 41 is supported versus housing 44 via a lower and an upper antifriction bearing 42 and, respectively, 43 , and against inner ring 8 of the bearing of the rotating rim on the other hand. The motor winding 45 is secured in housing 44 . The end of electric motor shaft 33 disposed opposite pinion tooth system 32 is extending from motor housing 44 and connects a steering fork.
The single-wheel driving mechanism is driven via drive motor 2 , to which voltage can be admitted, via pinion tooth system 32 of driving shaft 33 . The drive is acting directly on spur gear 30 , which is connected with driving shaft 24 with torsional strength and transmits the torque to bevel pinion 29 , and from the latter via tooth system 21 , 22 to bevel gear 11 , which is connected with torsional strength with rim 10 of the running wheel, or the running wheel 9 . The pivotal movement of steering drive mechanism 1 is assured by bearing 5 of the rotating rim and may take place via the steering fork (not shown). As compared to the known prior art, the embodiment of the single-wheel driving mechanism as defined by the invention requires no running wheel shaft, which results in a saving of costs, and facilitates the installation or removal of the driving mechanism. Furthermore, the construction is characterized by a relatively simple structure of the housing 3 and, owing to the direct coupling provided between running wheel 9 and bevel gear 11 , leads to a particularly advantageous transmission of the torque to running wheel 9 . In addition, arranging antifriction bearings 25 and 26 for driving shaft 24 outside of spur gear 30 and the bevel pinion 29 provides the possibility for permitting a particularly favorable small amount of play between the wall of the transmission and the driven running wheel. Furthermore, owing to the inventive embodiment, it is possible to have the smallest possible spacing between driving shaft 24 and electric motor shaft 33 in the presence of the same or superior transmission of the torque.
FIG. 2 shows a cut side view of another embodiment of a single-wheel driving mechanism 50 comprised of a drive motor 2 , a housing 51 with a two-stage gearing 4 , and a rotating rim bearing 5 for pivotably supporting housing 51 .
The structure of single-wheel driving mechanism 50 corresponds almost completely with the embodiment according to FIG. 1 . Only the housing 51 is different from the housing shown in FIG. 1 on account of its shape. Instead of a pivot of the housing, the lower area of the housing 51 comprises a passage (or breakthrough) 52 , which is provided for receiving a shaft journal 53 . This shaft journal 53 is pressed into passage 52 in such a way that it is received in housing 51 with torsional strength. In the exemplified embodiment shown, shaft journal 53 is provided with a flange-shaped collar 54 that comes to rest in a recess 55 of housing 51 . The shaft journal 53 penetrates the entire lower part of housing 51 and, furthermore, serves for receiving the antifriction bearings 15 , 16 in the manner shown already from FIG. 1 . Said bearings, furthermore, receive a bevel gear 56 in a supporting manner. As compared to the known design, bevel gear 56 has a pot-shaped attachment 57 pointing in the direction of running wheel 9 . Running wheel 9 with its rim 58 , which deviates in a minor way from the earlier form as well, is secured on said attachment by screw bolts 59 . A contact pressure-exerting disk 60 fixes antifriction bearings 15 and 16 . Disk 60 has a chamfer 61 and is directly screwed to shaft journal 53 by means of screw bolt 18 . Because the contact pressure-exerting disk 60 has a diameter that is dimensioned slightly larger than the one of shaft journal 53 , antifriction bearings 15 , 16 are fixed in their positions on outer surface 62 of the shaft journal 53 . A covering cap 62 again closes a passage bore extending through to screw bolt 18 , 50 that no dirt can penetrate antifriction bearing 15 , 16 . By realizing a housing 51 with a shaft journal 53 pressed into a passage (or breakthrough) 52 , housing 51 is additionally reinforced in the lower area and, furthermore, the manufacture of housing 51 is facilitated in terms of casting technology. In all other respects, the single-wheel driving mechanism 50 offers the same technical advantages as the embodiment shown in FIG. 1 .
FIG. 3 shows a further sectional side view of a single-wheel driving mechanism 70 that is also comprised of a drive motor 2 , a housing 71 with a two-stage gearing 4 , and a rotating rim bearing 5 for pivotably supporting housing 71 . The construction of the single-wheel driving mechanism 70 is approximately identical with the one of single-wheel driving mechanisms 1 and 50 according to FIGS. 1 and 2 , respectively. However, deviations ensue on account of the fact that a pump device 73 is additionally received in a pivot 72 of the housing. Pump device 73 is comprised of a tappet 74 , which is supported in an axially movable manner in a bore 75 of pivot 72 of the housing. Tappet 74 is acting on a pressure chamber 76 , which is connected with an outlet valve 77 and an inlet valve 78 . Inlet valve 78 feeds into a lower interior space 79 of the housing, which, as a rule, is completely filled with oil. Outlet valve 77 , on the other hand, is connected via a connection channel 80 with a bore 81 centrally extending in driving shaft 24 . Bore 81 is extending up to above the antifriction bearing 26 provided for supporting the driving shaft 24 . Due to the action of the pump, the oil is therefore pumped from interior space 79 of the housing and via inlet valve 78 and outlet valve 77 located within the bore 81 , up to antifriction bearing 26 , from where it supplies both the driving shaft 24 and the other components of the gearing with an adequate amount of oil.
In the embodiment shown, tappet 74 is pressed by a spring 82 against a pot-shaped attachment 84 of bevel gear 83 , and rests in a groove 85 that is arranged in the form of a ring around screw bolt 18 , and comprises a wavelike deepening, so that when running wheel 9 is rotating, tappet 74 is put into an axial motion against the spring force of the spring 82 . The opposite end of tappet 74 is sealed off against pressure chamber 76 to the extent that it possible to obtain a suction and pressure effect. So that tappet 74 is capable of engaging the groove 85 , the contact pressure-exerting disk 86 has a passage (or breakthrough) 87 .
Accordingly, while only a few embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.
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A single-wheel driving mechanism for floor transport vehicles is comprised of a gearing housing with at least one gear stage, a flanged-on drive motor, and a driven running wheel. For obtaining the smallest possible installation space or achieving a simplified installation or removal of the single-wheel driving mechanism, in conjunction with high transmission of force at the same time, the running wheel is directly connected with torsional strength with a gear of the transmission, and the gear of the transmission is rotatably supported on a support element.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to water saving devices for toilet flush tanks. More specifically, the invention is an adjustable attachment for flush mechanisms that terminates a flush before the entire volume of water in the tank has exited.
2. Description of the Prior Art
Saving water in toilet flush tanks is a matter of current concern in many water short areas of the country, and a variety of devices are known for reducing the volume of each flush. Most popular is a brick placed in the flush tank to displace its volume in water. More elaborate devices include liners for the tank, which likewise displace a volume of water. While these devices accomplish the task of reducing water volume per flush, they also reduce the efficiency of the flush by reducing the weight of water available behind the initial water rushing into the toilet bowl. In addition, bricks and like fillers may interfere with the free operation of the float connected to the water inlet valve.
Another approach often tried is a modified structure for the flushing mechanism, often involving special levers and arms for locking the water outlet plug in predetermined positions. Such modified mechanisms are restricted in use to flush tanks having sufficient space and proper design to receive the new mechanisms. Most modified mechanisms are designed for use with an outlet plug as shown in FIG. 6 and are not adaptable to the more modern flap shown in FIG. 7. Thus, a person wishing to save water by using a prior art device must install a new tank or flushing mechanism, often at prohibitive expense. In addition, complex lever systems are unsatisfactory because of the natural scale that builds on submerged plumbing and can cause malfunction.
SUMMARY OF THE INVENTION
A flush interrupter has a tank or float of adjustable buoyancy and weight and is connected to the tank outlet plug means as an attachment that closes the plug means before the entire volume of tank water has exited during a flush. The invention is applicable to most known flush mechanisms without replacing any part of the existing flush mechanism. An adapter that connects to the chain of flapper valve plug means allows the flush interrupter to operate on flaps. One embodiment of the flush interrupter is a float on a chain that clips to the outlet plug means, and a second embodiment is a sealed tank that is directly attached to the outlet plug means.
An object of the invention is to provide an attachment for flush mechanisms that can be applied to existing mechanisms at modest cost and with minimal effort. While saving water is a popular concept, most people are not willing to spend the price of a new toilet flush tank or new flush mechanism just to save a few gallons of water per flush. This invention is both low in cost and adaptable to almost any existing flush mechanism, and, in addition, the user can install and adjust the invention in a few minutes.
An important object is to provide a simple flush interrupter that can be adapted to the individual characteristics of each flush mechanism and that will operate dependably. The invention is adjustable in its buoyancy and weight so that the user can adjust it to compensate for corrosion on his flush mechanism and for the specific size and characteristics of his tank outlet plug means. In addition, the amount of water delivered per flush is adjustable by changing the position of the interrupter on the tank outlet plug means. The simple design of the invention and the basic concept of delivering weight to prematurely close the tank outlet plug means allow the interrupter to operate without complex mechanism.
Another important object is to allow the toilet tank to deliver its full volume of water whenever desired. The flush interrupter operates automatically whenever the tank is flushed normally, but a user can overcome the invention by holding the flush lever in flush position for an extra second or two, thereby allowing the entire volume of water in the flush tank to flow into the toilet bowl for full flushing action.
A further object is to create a flush interrupter that will not interfere with the operation of parts of the flushing mechanism other than the tank outlet plug means. The two embodiments of the invention revealed below are independent of the water intake valve and its float.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of one embodiment of the flush interrupter.
FIG. 2 is a top plan view of the clip shown in FIG. 1.
FIG. 3 is an elevational view of an adapter used with the invention.
FIG. 4 is an elevational view showing a second embodiment of the invention.
FIG. 5 is a top plan view o the invention shown in FIG. 4.
FIG. 6 is an elevational view of one embodiment of the invention attached to the plug means of a toilet tank.
FIG. 7 is a view similar to FIG. 6 showing the invention attached to a flapper valve plug means.
FIG. 8 is a view similar to FIG. 6 showing the invention attached to another variety of plug means.
FIG. 9 is a view similar to FIG. 6 showing the second embodiment of the invention attached to a flapper valve plug means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The flush interrupter 10 is an attachment that may be adapted to fit the flushing mechanism of most known flush tanks and thereby cause the flushing mechanism in the tank to flush the associated toilet with less than a full tank of water. One embodiment of the interrupter includes a weighted float 12 having an attached chain 13 and clip means attached to the chain, for example two way clip 14.
Float 12 is independent of the float ball found on the water inlet valve of many flushing mechanisms. It may be equipped with an aperture 15 that may be sealed with plug means such as a screw. The function of float 12 is to be a weight that returns the water outlet plug means of the flush tank to its seat before the entire volume of water in the tank has emptied through the tank outlet. Aperture 15 allows water or other heavy material to be sealed inside the float by the plug means, thereby allowing float 12 to have adjustable buoyancy for the particular needs of the flushing mechanism with which it is used.
Chain 13 and clip 14 attach float 12 to the outlet plug means of the flush mechanism. Chain 13 is attached at a first end to float 12 and has its second end passing through an opening of clip 14, where it is secured by fastening means, such as screw 20. Clip 14 is secured to the flushing mechanism of a toilet tank by fastening means, such as screw 21. The length of chain between float 12 and clip 14 may be adjusted by loosening screw 20, sliding the chain through clip 14 to the desired length, and retightening screw 20. Clip 14 is designed to attach selectively to either vertical or horizontal edges and may have chain openings 25 and 26 at right angles so that the float and chain will hang vertically as shown in the drawings.
The method of attaching the flush interrupter 10 to populaar flush mechanisms is shown in FIGS. 6-8. Clip 14 is attached to the wire stem 30 of plug 31 of the mechanism of FIG. 6. Modern flush mechanisms using a flapper valve 35, as shown in FIG. 7, have a chain 36 instead of a wire stem to lift the flap. A special adapter 40 may be installed along the length of chain 36 to provide means along which flush interrupter 10 may act to lower flap 35. As shown in FIG. 3, adapter 40 has chain engaging hooks 42 at both top and bottom ends. Connector 44 has a central threaded bore that receives oppositely threaded inner ends 45 and 46 of adapter 40. By turning connector 44 in a first direction, the ends 45 and 46 are moved together, shortening the length of adapter 40 so that hooks 42 may engage links of chain 36. Connector 44 may then be turned in the opposite direction to lengther adapter 40, firmly securing the adapter to chain 36. Clip 14 of flush interrupter 10 may then be attached directly to adapter 40. Some flush tanks are equipped with a wide stem 50 on the outlet plug o the flush tank, as shown in FIG. 8. Clip 14 may be attached to the upper flange 51 os such plugs.
In operation, float 12 may have its weight adjusted for desired buoyancy on the particular mechanism in the flush tank. For most applications, the float should contain enough air to support its own weight in the tank water and to avoid premature termination of the flushing operation. When the flush is initiated by turning the handle on the tank, the flap 35 or plug 31 or 50, as the case may be, is raised, allowing water to flow from the tank to the toilet bowl below. As the water level drops, the float 12 is lowered until its weight is suspended from chain 13, at which time the weight of the float acts to return flap 35 or plug 31 or 50 to its seat, saving a substantial volume of water. The volume of water used for each flush may be adjusted by changing the length of chain 13 between float 12 and clip 14. If a flush using the entire volume of water in the tank is desired, the mechanism is easily overridden by engaging the flush initiating handle of the tank for an extended period of time, thereby holding the flap or plug out of its seat until the entire volume of tank water has exited.
A second embodiment of the flush interrupter 10' is shown in FIGS. 4 and 5. This version includes a cylindrical tank 60 having a hollow tube 62 through its center. The tank 60 may have an aperture 63 sealed by a screw 64 or other sealing means, allowing the tank to be partially filled with heavy material to adjust its buoyancy, as was previously described in connection with float 12.
Flush interrupter 10' may be attached to any of the previously described flushing mechanisms. Tank 60 may be attached to the wire stem 30 of the mechanism in FIG. 6 by passing a portion of stem 30 through tube 62 and tightening mounting screw 67 against stem 30. As shown in FIG. 9, adapter 40 is used in conjunction with the chain 36 to attach interrupter 10' to flap 35. A modified version (not shown) having the interrupter 10' split vertically into two tanks could be applied to stem 50 of FIG. 8 and strapped together. This version would require such modifications as aperture 63 and sealing screw 64 in each of the tanks and the addition of a strap for fastening the halves together.
Preferred materials for the flush interrupter include plastic float 12 or tank 60, brass for screw 64, chain 13, clip 14, and adapter 40. In addition, the strap around the modified version of interrupter 10' (not shown) may be of brass.
The operation of the flush interrupter allows water from the tank to enter the toilet bowl with the pressure of a full tank of water behind it, giving a vigorous flush but saving the final volume of water, which enters the bowl with low pressure behind it. Because the interrupter is adjustable in buoyancy its characteristics may be adapted to the needs of the individual flush mechanism, and it does not require the presence of the water inlet float or other hardware to aid its operation, other than an outlet plug to which the interrupter may be attached as herein disclosed.
Flush tanks usually deliver 6 gallons of water for each flush, but authorities in many water short areas have suggested that 3 gallons is sufficient for most purposes. Conversion from 6 to 3 gallons is possible by merely adding the flush interrupter to existing flush mechanisms, and the volume of water delivered may be further adjusted by altering the chain length with interrupter 10 or adjusting the mounting height of interrupter 10'. The present invention is believed to be a significant advance in the art both in its adaptability to known flush mechanisms and in its adjustability to individual preferences and requirements.
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An attachment for interrupting the flushing action of a toilet before the entire volume of water in the toilet tank has exited includes a buoyant member that is connected to the water outlet plug of the toilet tank and acts to close the plug when some but not all of the water in the tank has exited. The buoyant member is connected to the plug and closes the plug by applying its weight to the plug when the member is no longer supported by the water. An adapter allows the buoyant member to act on flapper valves as well as on conventional tank plugs.
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The entire disclosure of Japanese Patent Application No. 2000-203529 filed on Jul. 5, 2000 including specification, claims, drawings and summary is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for producing reduced iron by reducing pellets or briquette-like agglomerates, formed from a powdery mixture of an iron oxide powder and a reducing agent, in a high temperature atmosphere.
2. Description of the Related Art
To produce reduced iron, the first step is, generally, to mix a powder of iron ore (iron oxide), a powder of coal (reducing agent), a powder of limestone (fluxing agent), and a binder such as bentonite, and to compress and pelletize the mixture to form wet balls called green balls. Then, the wet balls are dried to some degree to form dry balls. The dry balls are heated to a high temperature in a reducing furnace, where iron oxide in the iron ore is reduced with the coal as a reducing agent to form reduced iron in the form of pellets.
An example of a conventional apparatus for producing reduced iron is explained by way of FIG. 6 . Powders of iron ore, coal, etc. and a binder are mixed in a mixer (not shown). The resulting mixed powder is pelletized in a pelletizer 001 to form green balls (raw pellets) GB. Then, the green balls GB are charged into a dryer 002 , where they are dried with an off-gas from a reducing furnace 004 (to be described later on) to form dry balls DB. The dry balls DB are supplied to the reducing furnace 004 by a pellet feeder 003 .
The interior of the reducing furnace 004 is maintained in a high temperature atmosphere upon heating by a burner 005 , and an inside off-gas is discharged from an off-gas duct 006 . Thus, the dry balls DB are preheated and heated with radiant heat from the wall of the furnace when they are passed through the interior of the reducing furnace 004 . During their passage, the iron oxide in the iron ore is reduced with the coal as the reducing agent to form reduced iron in the form of pellets. The reduced pellets are discharged into a pellet discharger 008 , and accommodated into a portable vessel 009 .
The off-gas from the off-gas duct 006 usually contains some unburned gas, and is thus burned in an after burner chamber 007 nearly completely. Then, the off-gas is cooled in a water spray primary cooler 010 , and then sent to a heat exchanger 011 , where it undergoes heat exchange to heat combustion air. Combustion air heated by the heat exchange is sent to the reducing furnace 004 , and fed into the furnace together with a fuel. On the other hand, the off-gas is cooled again in a secondary cooler 012 , and part of it is sent to the dryer 002 as drying air for the green balls GB as stated earlier. All of the off-gas is then cleaned in a dust collector 013 , and released into the atmosphere via a stack 014 .
In the conventional apparatus for producing reduced iron, as described above, heat exchange is performed by the heat exchanger 011 between the off-gas discharged from the reducing furnace 004 and combustion air. The heated combustion air is supplied to the reducing furnace 004 , where the dry balls DB are preheated and heated with radiant heat from the furnace wall. The temperature of the off-gas may be as high as about 1,300° C., so that the off-gas has a great amount of thermal energy. Conversely, the metallic recuperative heat exchanger 011 is thermally resistant to temperatures of about 900° C. or lower because of its structure. Thus, the off-gas is cooled by the water spray primary cooler 010 before it is sent to the heat exchanger 011 . The dryer 002 for the green balls GB has a structure designed only to perform drying of the green balls GB. To prevent rupture of the pellets, the gas for drying also needs to be cooled to about 300° C. or lower (desirably about 270° C.). To adjust the temperature of the off-gas from the recuperative heat exchanger 011 , the water spray secondary cooler 012 is provided to add water into the off-gas and lower the temperature of the gas to be supplied to the dryer 002 , by utilizing the heat of vaporization of water.
As described above, the secondary cooler 012 is also needed in addition to the water spray primary cooler 010 , so that the system for treatment of the off-gas is complicated. Besides, the amount of the off-gas increases at least by the amount of the water sprays used. Thus, the treatment system for the off-gas is upsized. Moreover, the dry balls DB are preheated by the radiant heat with low thermal efficiency in the reducing furnace 004 , and the latent heat of evaporation of the off-gas is taken away by the water spray. That is, much of the heat in the off-gas is wasted. For such reasons, recovery of the sensible heat possessed by the off-gas (i.e., effective use of the sensible heat) is insufficient. Hence, consumption of fuel used in the reducing furnace 004 is increased thereby raising the fuel cost, and the equipment (reducing furnace) is upsized.
SUMMARY OF THE INVENTION
The present invention has been proposed in light of these circumstances. It is an object of this invention to provide an apparatus for producing reduced iron, which can decrease the fuel cost and downsize the equipment by effective use of the sensible heat of the off-gas discharged from the reducing means, and which can downsize and simplify a system for treatment of the off-gas by decreasing the amount of the off-gas.
According to the present invention, as a means of attaining the above object, there is provided an apparatus for, producing reduced iron by drying agglomerates, which are pelletized from a powdery mixture of an iron oxide powder and a reducing agent, by a drying means; preheating the dried agglomerates by a preheating means; and then reducing the preheated agglomerates in a high temperature atmosphere of a reducing means, wherein the preheating means convects an off-gas from the reducing means to preheat the dried agglomerates. Thus, a decrease in the fuel cost, and a downsizing of the equipment can be achieved by the effective use of the sensible heat carried by the off-gas discharged from the reducing means. Moreover, a downsized, simplified system for treatment of the off-gas is realized by decreasing the amount of the off-gas.
In the apparatus for producing reduced iron, the drying means and the preheating means may be integrally formed as a drying preheater for drying and preheating a continuous flow of the agglomerates. Thus, the reducing means can be downsized, and the drying preheater can be made more compactly.
In the apparatus for producing reduced iron, a combustion means may be provided for burning any unburned gas in the merged off-gas, and part of the off-gas from the combustion means may be cooled with air and supplied to the drying means to dry the agglomerates. Thus, the unburned gas in the off-gas flowing in the off-gas circulation loop can be completely burned, and the temperature of the off-gas fed to the drying means can be lowered effectively.
In the apparatus for producing reduced iron, any unburned gas contained in the part of the off-gas discharged from the preheating means may be burned using part of the combustion air which is supplied to the reducing means, and then the part of the off-gas may be supplied to the drying means. Thus, the unburned gas can be burned effectively, and this is useful when dry distilled coal or the like is used as the reducing agent in the raw pellets.
In the apparatus for producing reduced iron, a regenerative heat exchanger may be provided for heating combustion air to be supplied to the reducing means. Thus, the amount of the off-gas and the fuel for heating of the reducing means can be further decreased overall.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic drawing of an apparatus for producing reduced iron, showing a first embodiment of the present invention;
FIG. 2 is a schematic drawing of an apparatus for producing reduced iron, showing a second embodiment of the present invention;
FIG. 3 is a schematic drawing of an apparatus for producing reduced iron, showing a third embodiment of the present invention;
FIG. 4 is a schematic drawing of an apparatus for producing reduced iron, showing a fourth embodiment of the present invention;
FIG. 5 is a schematic drawing of an apparatus for producing reduced iron, showing a fifth embodiment of the present invention; and
FIG. 6 is a schematic drawing of a conventional apparatus for producing reduced iron.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which in no way limit the invention.
First Embodiment
FIG. 1 is a schematic drawing of an apparatus for producing reduced iron, showing a first embodiment of the present invention.
As shown in FIG. 1, a powder of iron ore (iron material), a carbonaceous powder (reducing agent) such as coal, and a powder of a flux such as limestone, which are materials for pellets, and if desired, a powder of a binder such as bentonite are mixed and kneaded in a mixer (not shown) with the addition of a predetermined amount of water to form a mixed powder. The mixed powder is pelletized in a pelletizer 1 to form green balls GB (raw pellets as agglomerates) of about 10 to 20 mm in diameter. These green balls GB are charged into a drying chamber (drying means) 3 constituting the first half of a drying preheater 2 . In the drying chamber 3 , the green balls GB are dried with a mixed gas to become dry balls DB. The mixed gas is a mixture of an off-gas from a preheating chamber (preheating means) 5 , which is separated from the drying chamber 3 by a bulkhead 4 to constitute the latter half of the drying preheater 2 , and room-temperature air which is introduced by an air blower 6 . The off-gas and the room-temperature air are mixed in a gas merging portion 7 , where the mixture is adjusted to a predetermined temperature (about 250° C. at which the green balls GB do not rupture). Then, the mixture is fed to the drying chamber 3 as the mixed gas. The gas discharged from the drying chamber 3 is guided by piping 8 , treated by a gas cleaning device such as a dust collector 9 , and then released into the atmosphere via a stack 10 .
The dry balls DB are then fed to the preheating chamber 5 continuously by a conveyor or the like. In the preheating chamber 5 , an off-gas from a rotary hearth reducing furnace (reducing means) 11 (to be described later on) is passed over the dry balls DB (convected for heat transfer) to preheat the dry balls DB to about 450° C. The dry balls DB preheated to about 450° C. are then supplied to the reducing furnace 11 by a pellet feeder 12 .
A burner (group) 13 is mounted in the reducing furnace 11 to heat and maintain its interior in a high temperature atmosphere, and an off-gas can be discharged from an off-gas duct 14 (see the arrow 15 showing the direction of gas flow). Thus, when the dry balls DB move inside the reducing furnace 11 (see the arrow 16 showing the direction of hearth rotation), they are heated to a high temperature, and the iron oxide powder is reduced by the carbonaceous powder inside the pellets, whereby the pellet-shaped iron oxide can be formed. The reduced pellets (reduced iron pellets) are carried out of the reducing furnace 11 by a screw conveyor type of pellet discharger 17 , accommodated into a portable vessel 18 , and transported to a subsequent step.
On the other hand, the off-gas which is at a high temperature (1200 to 1300° C.) is discharged from the off-gas duct 14 and is sent to an after burner chamber 19 , where any unburned gas, such as CO gas, in the off-gas is completely burned. Then, the off-gas is sent to a water spray gas cooler 20 , where it is cooled to about 900° C. Then, the off-gas is sent to a recuperative heat exchanger 21 , where the off-gas exchanges heat with combustion air for the reducing furnace heating burner 13 as stated above. Then, the off-gas is guided into the preheating chamber 5 of the aforementioned drying preheater 2 via piping 22 . The gas temperature at the inlet of the preheating chamber 5 is about 570° C. The dry balls DB after drying are preheated to about 450° C., discharged from the preheating chamber 5 , and charged into the aforementioned reducing furnace 11 . On the other hand, the off-gas, which has finished preheating of the dry balls DB, reaches about 360° C., and exits from the preheating chamber 5 . Then, the off-gas is sent to the aforementioned gas merging portion 7 via piping 23 . On the other hand, the combustion air, which has been preheated to about 450° C. in the recuperative heat exchanger 21 , is guided to the burner 13 via piping 24 for use as the combustion air for heating the reducing furnace 11 .
According to the present embodiment, as described above, the convection type preheating chamber 5 is provided as the latter half of the drying chamber 3 for drying the green balls GB. The off-gas from the recuperative heat exchanger 21 is directly fed to the preheating chamber 5 to preheat the dried pellets (dry balls DB) efficiently to about 450° C. Thus, the carry-in energy (sensible heat) of the pellets when charged into the reducing furnace 11 increases, so that the fuel used by the burner (group) 13 can be decreased, on a natural gas basis, by about 30 Nm 3 (220 Nm 3 minus 190 Nm 3 ) per ton of reduced iron. In addition to the efficient preheating of the pellets by convective heat transfer in the preheating chamber 5 outside the reducing furnace 11 , the drying means and preheating means are integrally formed as the drying preheater 2 , whereby drying and preheating are performed for a continuous flow of the pellets. Thus, the reducing furnace 11 can be downsized, and compactness of the drying preheater 2 can be achieved. Furthermore, the off-gas discharged from the preheating chamber 5 is mixed with and cooled with air introduced by the air blower 6 . Therefore, a conventional water spray secondary cooler 012 (see FIG. 6) becomes unnecessary. As a result, the loss of the latent heat of evaporation of the off-gas is prevented to improve thermal efficiency further. Besides, a decrease in the amount of the off-gas results in the downsizing and simplification of the off-gas treatment system.
Second Embodiment
FIG. 2 is a schematic drawing of an apparatus for producing reduced iron, showing a second embodiment of the present invention. In the present embodiment, the preheating chamber 5 of the drying preheater 2 and the off-gas duct 14 upstream of the after burner chamber 19 are connected together by piping 25 so that the off-gas discharged from the preheating chamber 5 is merged with the off-gas from the reducing furnace 11 at a gas merging portion 26 , and the aforementioned piping 22 , piping 25 , etc. constitute an off-gas circulation loop.
Furthermore, piping 28 is branched from the off-gas duct 14 downstream of the after burner chamber 19 , so that the off-gas having any unburned gas, such as CO gas, is completely burned by the after burner chamber 19 and then is partly branched at a gas branching portion 27 , and is guided to the drying chamber 3 of the drying preheater 2 . In this state, the temperature of the off-gas may be as high as about 950° C. Like the First Embodiment, therefore, the off-gas is mixed, at the gas merging portion 7 , with room-temperature air introduced by the air blower 6 . Consequently, the off-gas is adjusted to about 250° C., a temperature at which the green balls GB do not rupture.
Other features are the same as in the First Embodiment. Thus, the same members as in the First Embodiment will be assigned the same numerals, and duplicate explanations will be omitted.
In the present embodiment, the same actions and effects as in the First Embodiment are obtained. In the present embodiment, moreover, part (40 to 70%) of the off-gas discharged from the after burner chamber 19 is branched, and directly allocated to drying of the green balls GB. Thus, drying of the green balls GB is efficiently performed, and the amount of the gas passing through the recuperative heat exchanger 21 , which is restricted by the gas temperature at the inlet, can be decreased to about a half or less of the conventional amount of the gas. Hence, the amount of water spray in the water spray gas cooler 20 provided ahead of the recuperative heat exchanger 21 can be cut down. As a result, the final amount of the off-gas discharged from the stack 10 can be decreased by about 500 Nm 3 (1800 Nm 3 minus 1300 Nm 3 ) per ton of reduced iron in comparison with the conventional apparatus.
Third Embodiment
FIG. 3 is a schematic drawing of an apparatus for producing reduced iron, showing a third embodiment of the present invention. In the present embodiment, the temperature of the combustion air for the reducing furnace which is preheated by the recuperative heat exchanger 21 as in the preceding Second Embodiment is raised to about 1,000° C. with the use of a regenerative heat exchanger. That is, in FIG. 3, the reference numerals 31 and 32 each denote a regenerative heat exchanger. These heat exchangers 31 and 32 are alternately heated with a high temperature combustion gas sent from a burner chamber 33 . The numerals 30 and 36 denote flow selector valves for the preheated combustion air. The numerals 34 and 35 denote flow selector valves for a high temperature combustion gas for the heat exchangers 31 , 32 .
In FIG. 3, solid lines show a state currently in use, while dashed lines show a state after flow selection. That is, combustion air is preheated to about 450° C. in the recuperative heat exchanger 21 , then passes through piping 24 , and enters the heat exchanger 31 via the flow selector valve 30 . In the heat exchanger 31 , the combustion air is preheated to about 1,000° C., then passes through the flow selector valve 36 , and finds use as combustion air for heating the reducing furnace 11 after flowing in piping 37 . On the other hand, a high temperature combustion gas at about 1,500° C. produced by burning a natural gas or the like with air in the burner chamber 33 is guided to the other heat exchanger 32 via the flow selector valve 34 to heat (regenerate) the heat exchanger 32 . Then, the gas is discharged from the heat exchanger 32 as a low temperature off-gas of about 150° C., sent to the stack 10 via the flow selector valve 35 and piping 38 , and released into the atmosphere.
Other features are the same as in the Second Embodiment. Thus, the same members as in the Second Embodiment will be assigned the same numerals, and duplicate explanations will be omitted.
In the present embodiment as well, the same actions and effects as in the Second Embodiment are obtained. In the present embodiment, moreover, the preheating temperature of combustion air for the reducing furnace can be raised from about 450° C. in the Second Embodiment to as high as about 1,000° C. Thus, the overall amount of off-gas can be decreased by about 600 Nm 3 (1800 Nm 3 minus 1200 Nm 3 ) per ton of reduced iron. Also, fuel for heating of the reducing furnace can be decreased by about 40 Nm 3 (220 Nm 3 minus 180 Nm 3 ) when a natural gas is used.
Fourth Embodiment
FIG. 4 is a schematic drawing of an apparatus for producing reduced iron, showing a fourth embodiment of the present invention. In the present embodiment, piping 40 from the after burner chamber 19 is connected to a site midway through the piping 22 connecting the recuperative heat exchanger 21 and the preheating chamber 5 of the drying preheater 2 in the aforementioned First Embodiment. Furthermore, piping 42 branched from the piping 23 connecting the preheating chamber 5 (its wind box) and the gas merging portion 7 is directly connected to the recuperative heat exchanger 21 . In this manner, an off-gas circulation loop is formed from the piping 22 , piping 42 , etc. Other features are the same as in the First Embodiment. Thus, the same members as in the First Embodiment will be assigned the same numerals, and duplicate explanations will be omitted.
According to the above configuration, an off-gas discharged from the off-gas duct 14 is sent to the after burner chamber 19 , where any unburned gas, such as CO gas, in the off-gas is completely burned. Then, the off-gas is fed to the preheating chamber 5 via the piping 40 and a gas merging portion 41 . The temperature of the off-gas which has just left the after burner chamber 19 may be as high as about 1,200° C. or above. Thus, the off-gas is mixed and diluted, at the gas merging portion 41 , with a circulating off-gas which is fed from the recuperative heat exchanger 21 via the piping 22 . The mixed gas is adjusted to a temperature of about 750 to 800° C., and fed in this state to the preheating chamber 5 . Pellets are preheated with this gas to about 750° C., and discharged from the preheating chamber 5 .
The off-gas, which has finished preheating of the pellets, cools to about 640° C., and is discharged from the preheating chamber 5 . Then, the off-gas is sent again to the recuperative heat exchanger 21 via the piping 42 . In the heat exchanger 21 , the off-gas exchanges heat with combustion air for the reducing furnace heating burner 13 , and is then circulated via the piping 22 for reuse in preheating of pellets. The temperature of the circulating off-gas at the outlet of the recuperative heat exchanger 21 is about 430° C.
On the other hand, the off-gas discharged from the preheating chamber 5 is partly branched at a gas branching portion 43 , and is guided to the drying chamber 3 via the piping 23 . In this state, the temperature of the off-gas at the inlet of the drying chamber may be as high as about 640° C. as stated above. Like the First Embodiment, therefore, the off-gas is mixed, at the gas merging portion 7 , with room-temperature air introduced by the air blower 6 . Consequently, the off-gas is adjusted to about 250° C., a temperature at which the green balls GB do not rupture.
In the present embodiment, like the First Embodiment, the pellets after drying are subsequently preheated to about 750° C. with high efficiency. As the carry-in energy (sensible heat) of the pellets when charged into the reducing furnace 11 increases, the fuel used by the reducing furnace heating burner 13 can be decreased, on a natural gas basis, by about 50 Nm 3 (220 Nm 3 minus 170 Nm 3 ) per ton of a reduced iron product. In the present embodiment, moreover, the off-gas after preheating of the pellets is discharged at a low temperature of about 640° C. Thus, this gas can be directly fed, unchanged, to the recuperative heat exchanger 21 , and the off-gas that has left the recuperative heat exchanger 21 may have a high temperature, since it is fed to the preheating chamber 5 . These advantages make it unnecessary to provide a water spray cooler immediately behind the recuperative heat exchanger 21 , as was done in the conventional example. Hence, there is no problem of the amount of the off-gas increasing with the use of a water spray. Compared with the conventional example, therefore, the final amount of the off-gas can be decreased by about 800 Nm 3 (1800 Nm 3 minus 1000 Nm 3 ) per ton of reduced iron.
In addition, the present embodiment can be applied when preparing raw pellets mainly from ironwork dust occurring in ironworks, etc., and drying, preheating and reducing the pellets. The ironwork dust already contains a carbonaceous powder scant in volatiles as a reducing agent. Thus, when the pellets are preheated at a high temperature, few volatiles are contained in the off-gas from the preheating chamber 5 .
Fifth Embodiment
FIG. 5 is a schematic drawing of an apparatus for producing reduced iron, showing a fifth embodiment of the present invention. The present embodiment is a modification of the Fourth Embodiment which uses dry distilled coal as a reducing agent for raw pellets. In FIG. 5, the same members as in FIG. 4 illustrating the Fourth Embodiment will be assigned the same numerals, and duplicate explanations will be omitted.
As the pellets are preheated at a high temperature (about 750° C.) in the preheating chamber 5 , the off-gas discharged from the preheating chamber 5 (its wind box), no doubt, contains volatiles (combustible gas). Thus, part of the off-gas from the preheating chamber 5 is guided to an after burner chamber 44 via the gas branching portion 43 and piping 23 , as shown in FIG. 5 . In the after burner chamber 44 , unburned matter (combustible gas) contained in the off-gas is burned. Air for this burning is obtained in the following manner: Combustion air for the reducing furnace heating burner 13 is preheated to about 450° C. in the recuperative heat exchanger 21 , and branched at a gas branching portion 45 . The branched air passes through piping 46 , and is introduced into the after burner chamber 44 , where it is used as the above-mentioned air for combustion of the unburned matter. The off-gas having the unburned matter completely burned is mixed and diluted, at the gas merging portion 7 , with room-temperature air introduced by the air blower 6 . As a result, the mixed gas is adjusted to a gas temperature of about 250° C. Then, the gas is fed into the drying chamber 3 to dry the raw pellets. The gas discharged from the drying chamber 3 is guided by piping 8 , treated by a gas cleaning device such as dust collector 9 , and then released into the atmosphere via the stack 10 .
In the present embodiment, like the Fourth Embodiment, the pellets after drying are subsequently preheated to about 750° C. with high efficiency. As the carry-in energy (sensible heat) of the pellets when charged into the reducing furnace 11 increases, the fuel used by the reducing furnace heating burner 13 can be decreased, on a natural gas basis, by about 50 Nm 3 (220 Nm 3 minus 170 Nm 3 ) per ton of a reduced iron product. Furthermore, like the Fourth Embodiment, water spray is not introduced for cooling of the off-gas from the reducing furnace 11 . Thus, compared with the conventional example, the final amount of the off-gas discharged from the stack 10 can be decreased by about 650 Nm 3 (1800 Nm 3 minus 1150 Nm 3 ) per ton of a reduced iron product.
The present invention being thus described, it will be obvious that the same is not limited to the foregoing embodiments, but may be varied in many ways. For example, the embodiments have been illustrated, with the agglomerates of the materials for reduction being restricted to pellets. However, the invention can be applied similarly to briquettes as the agglomerates. Furthermore, in the First, Second, Fourth and Fifth Embodiments, the temperature of combustion air for the reducing furnace may be raised with the use of a regenerative heat exchanger. 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 apparatus for producing reduced iron dries agglomerates, pelletized from a powdery mixture of an iron oxide powder and a reducing agent, in a drying chamber, preheats the dried agglomerates in a preheating chamber, and then reduces the preheated agglomerates in a high temperature atmosphere of a reducing furnace. In the preheating chamber, an off-gas from the reducing furnace is convected to preheat the dried agglomerates. A decrease in the fuel cost, and downsizing of the equipment can be achieved by effective use of the sensible heat of the off-gas discharged from the reducing furnace. Moreover, a downsized, simplified system for treatment of the off-gas is realized by decreasing the amount of the off-gas.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 11/195,451 filed on Aug. 2, 2005 which is a divisional application of U.S. patent application Ser. No. 10/625,274 filed Jul. 23, 2003, now U.S. Pat. No. 7,010,845 which claims priority of U.S. patent application Ser. No. 09/647,603 filed Jan. 4, 2001, now abandoned which claims priority to PCT/EP99/02236 filed on 3 Oct. 2000 and to German Patent Application No. 198 15 407.0 filed Apr. 6, 1998.
FIELD OF THE INVENTION
[0002] The present invention relates to a fastener device which is or can be fixed at its one end to a first component by means of a joint which can be produced by a forming technique, preferably a riveted joint, and which has a receiving area configured or configurable to receive a bolt, a nut or another element, for example a bayonet part or a shaft. The present invention further relates to a combination of such a fastener device with one, two or three components and to a method of making a joint between a first and a second component while utilizing such a fastener device.
BACKGROUND OF THE INVENTION
[0003] A fastener device of the kind initially mentioned is known from a number of publications. European Patent 0 539 793, for example, discloses a nut element which can be introduced in a form-locked and force-transmitting manner into a component, in particular into a sheet metal part, by means of a method termed clamping hole riveting. Piercing bolts are also known from German patents P 30 03 908 and P 34 47 006 which can be inserted in a self-piercing manner into a component in the form of a sheet metal part, with the features of shape, which form the so-called piercing and riveting section of the bolt element, being provided on the side of the head remote from the shaft part of the bolt element, so that after the bolt element has been inserted into a component from one side, the shaft part of the bolt element extends away from the sheet metal part on this side.
[0004] Bolt elements are also known which can be inserted into a pre-punched component and can be fastened to the component in the region directly below the head of the bolt element by means of a joint which can be made by a forming technique. Such bolt elements are described, for example, in German Patent Application P 44 10 475. However, they can also be executed in a self-piercing design such as is set forth in the applicant's German Patent Application 195 35 537.7. With such so-called EBF bolts or self-piercing EBF bolts, once the joint to the component has been made, the head of the bolt element is arranged on the one side of the component and the shaft part with thread is located on the other side of the component.
[0005] Generally, all elements from the product range of Profil Verbindungstechnik GmbH & Co. KG, i.e. RND, RSN, HI, RSF, RSK, UM, RSU and FUN nut elements as well as EBF, SBK and SBF bolt elements, are suitable for the present invention. Almost all fastener elements which are known in the prior art for forming a joint by a forming technique to a component or a sheet metal part can also be used without any problem for the purposes of the present invention.
[0006] The preamble of claim 1 of the present application, which relates to a fastener device, basically covers all such fastener elements.
[0007] Reference is made to the following German patents and patent applications with respect to further information on the different fastener elements from the Profil company which are suitable for use in the present invention and with respect to the methods of manufacture and insertion which can be used: P 34 04 118, P 30 03 908, P 34 46 978, P 34 47 006, P 35 24 306, P 36 10 675, P 38 35 566, P 34 48 219, P 42 14 717, P 35 83663, P 4231 715, P 3439 583, P 689 08 903, P 691 01 491, P 44 10 475, P 42 112 78, P 42 11 276, P 43 10 953, P 44 20 426, P 44 29 737, 196 00 290.7, 195 35 537, 195 30 466, P 44 40 620, 196 47 831 and P 29 47 179.2. A number of various other industrial property rights of Profil Verbindungstechnik GmbH & Co. KG could also be named here.
[0008] All the above fastener elements are fastener elements which can be inserted into a sheet metal part, or optionally into a plurality of sheet metal parts contacting one another, and which then permit the screwing on of a further sheet metal part. The screwing on is carried out by means of a bolt or a nut which is screwed into or onto a fastener element made as a nut element or as a bolt respectively.
[0009] There is an increasing need in the sheet metal processing industry, but also in other industries, to screw a highly loaded component such as a mounting for an axle or a door hinge of an automobile to another component, for example a hollow section made up of a plurality of sheet metal parts, in such a way that an extremely stable attachment results. Such stable attachments can only be achieved for the production of such hollow parts with a greater amount of effort, particularly in view of the trend towards thin sheet metals.
[0010] One possibility to improve the stability of the mounting is to insert a spacer tube between two components spaced from one another and to achieve the screw connection via the spacer tube. The two sheet metal parts coupled via the spacer tube reinforce one another in this way. Furthermore, movements of the spacer tube with respect to the one or the other sheet metal part are suppressed by the attachment of the spacer tube at both ends, which is of benefit to the stability of the connection to the screw-on part.
[0011] Such spacer tube connections, see, for example, DE C 39 36 376, have, however, previously only been realized using welding processes. However, this produces the disadvantage that the positional accuracy of the metal sheets relative to one another is very low and the, as a rule, high dynamic permanent stresses cannot be borne without difficulty by the welded joints. Furthermore, the heat development during a welding process is not compatible with the strength requirements when high-strength, alloyed metal sheets are used.
[0012] It is the object of the present invention to provide a fastener device which can be used without difficulty in conventional sheet metal working, which can be realized at low cost and which allows a very stable attachment of a third component to a composite part comprising the first and second components and the fastener device.
SUMMARY OF THE INVENTION
[0013] In order to satisfy this object there is provided, in accordance with the invention, a fastener device of the kind named initially which is characterized in that it is configured in a region spaced from the first said end for attachment onto or into a second component. The spaced region can be provided in this arrangement at the end of the fastener device opposite the first said end. It can, however, also be at the center of the fastener device so that the other end of the fastener device projects beyond the second component.
[0014] Various possibilities exist for the attachment of the fastener device to the second component in the spaced region. For example, the spaced region can advantageously be designed as a blind-rivet sleeve. It can, however, also be designed for attachment to the second component by a forming technique, with it finally also being possible, depending on the specific embodiment, to design the spaced region such that it is suitable for welding or bonding to the second component.
[0015] The fastener device can be made in one piece or in a plurality of parts. The one piece design is, on the one hand, easy to handle, but has the disadvantage that the length of the fastener device always has to be adapted to the respective purpose, which makes stock-keeping more problematic. A design using a plurality of parts, however, allows such stock-keeping problems to be coped with—for example by the two ends of the fastener device being made by fastener elements available as standard parts which can in each case be joined to the associated sheet metal part by a forming technique, while a middle part termed a spacer tube can be made in different lengths depending on the application.
[0016] Particularly preferred embodiments of the fastener device can be found in the dependent claims 2 to 25 .
[0017] Special combinations of the fastener device and sheet metal parts can be found in the further claims 26 to 31 .
[0018] Methods of making a joint between a first and a second component while utilizing the fastener device in accordance with the invention can be found in claims 32 to 38 .
[0019] The fastener devices in accordance with the present invention in particular have the following advantages:
[0020] they permit the first and second components (sheet metal parts or moldings made of other materials) to be positioned with respect to one another with low tolerances with regard to the position and spacing of the moldings and thus form a kind of gauge during the assembly of the corresponding components;
[0021] they serve as a nut or bolt element for the screwing on of further components with heavy operating loads;
[0022] they serve to secure the angular position and—where required—the security against being pressed out or rotated during assembly;
[0023] they take up operating loads, shear and pressure torque statically and dynamically in each case;
[0024] the integrity of the fastener device is not a problem with the multiple part version either, as the screw connection can be made such that all elements of the fastener device are supported by one another.
[0025] It is of particular advantage that the shearing, tensile and compression forces as well as any torques, which have to be taken up at the end of the fastener device, can be taken up substantially better due to the length of the fastener device and the reinforcing of the structure it effects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention will be described in more detail in the following with reference to embodiments and the drawings in which are shown:
[0027] FIG. 1 a partly sectioned view of a first embodiment of the fastener device in accordance with the invention for an application with two components made of sheet metal;
[0028] FIG. 2 the same embodiment as FIG. 1 , but during the fastening of two components to one another;
[0029] FIG. 3 the completed joint between the two components of FIGS. 1 and 2 ;
[0030] FIG. 4 a partly sectioned longitudinal view of a second embodiment of a fastener device in accordance with the invention;
[0031] FIG. 5 a view of the fastener device of FIG. 4 partly sectioned in the longitudinal direction for an application with two components made of sheet metal;
[0032] FIG. 6 a representation similar to the lower part of FIG. 5 for an embodiment where the first component is made of two shaped sheet metal parts placed next to one another;
[0033] FIG. 7 a partly sectioned representation, similar to FIG. 5 , but for three different lengths of the fastener device in accordance with the invention of FIG. 4 , with the screwing on of a third component simultaneously being shown;
[0034] FIG. 8 a view partly sectioned in a longitudinal direction of a preferred embodiment in accordance with the invention of a fastener device having a blind-rivet sleeve and a blind-rivet mandrel;
[0035] FIG. 9 a representation similar to FIG. 8 , but after the insertion of the fastener device in accordance with the invention between two components composed of sheet metal, with the situation prior to the tightening of the blind-rivet joint being shown on the left side and the situation after the tightening of the blind-rivet joint on the right side.
[0036] FIG. 10 a representation of the lower part of a fastener device in accordance with the invention similar to FIG. 8 , but in a slightly modified embodiment;
[0037] FIG. 11 the lower part of the fastener device of FIG. 10 after insertion into a shaped sheet metal part;
[0038] FIG. 12 a slightly modified embodiment of the fastener device of FIG. 8 in a representation corresponding to FIG. 9 ;
[0039] FIG. 13 a view partly sectioned in a longitudinal direction of a further embodiment in accordance with the invention of a fastener device which represents the preferred embodiment;
[0040] FIG. 14 a schematic representation of the fastener device of FIG. 13 installed in two components;
[0041] FIGS. 15-21 representations similar to FIG. 7 , but of modified embodiments of the fastener device in accordance with the invention;
[0042] FIG. 22 a representation sectioned in a longitudinal direction of a three-part fastener device in accordance with the invention after the insertion into two components;
[0043] FIG. 23 a representation similar to FIG. 22 , but in a sloped position of the fastener device; and
[0044] FIG. 24 a representation sectioned in a longitudinal direction of a further embodiment in accordance with the invention of a fastener device;
[0045] FIGS. 25A to 25D various manufacturing steps for the installation of a fastener device in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0046] FIG. 1 first shows a fastener device 10 in accordance with the invention whose first lower end 12 is fastened to a first component 14 in the form of a shaped sheet metal part via a joint 11 which can be made by a forming technique. The joint made by a forming technique was made in this embodiment in accordance with German patent P 34 47 006. That is, the unitary fastener device 10 has a form at its lower first end corresponding to the so-called SBF (piercing bolt with flange) design of Profil Verbindungstechnik GmbH & Co. KG (hereinafter “Profil”) which leads to the joint with the component 14 shown in FIG. 1 after piercing and riveting. The noses 16 extending in a radial direction and forming rotational security between the fastener device 10 and the first component 14 can also be seen from FIG. 1 .
[0047] At its upper end 18 opposite the first said end 12 , the fastener device of FIG. 10 has a design corresponding to the RSF nut element (round shoulder nut with flange) of Profil which is made in accordance with German patent P 36 10 675. The upper end 18 of the fastener device 10 therefore substantially has the design of a nut element with a flange part 20 and with a piercing and riveting section 22 which merges into the flange 20 via a shoulder 24 extending substantially radially, with rotational security features 26 also being provided in the region of the shoulder. A thread cylinder 28 , which extends further in the direction of the central region of the fastener device 10 in this embodiment, is located within the flange part.
[0048] Although the upper end 18 of the fastener device is provided with a self-piercing design in the form of the piercing and riveting section 22 , in this variant of the embodiment the piercing and riveting section is not used for piercing; instead the second component 30 also designed as a shaped sheet metal part is pre-pierced. The hole is shown at 32 and is coaxial to the longitudinal axis 31 of the fastener device 10 and to the lower joint 11 made by a forming technique to the first component 14 .
[0049] There are substantially two reasons why the piercing and riveting section 22 is not used for self-piercing here. Primarily, there is a problem in that when the piercing and riveting section 22 is used to pierce the hole 32 in the component 30 , the slug would close the upper end of the fastener device 10 and thus prevent access to the thread cylinder. It would, however, be possible to subsequently remove the slug. But the fastener device 10 would have to be made hollow for this purpose so that a corresponding plunger could be inserted from the lower end. This can certainly be realized. However, after the making of the form-locked joint 12 , it would then first be necessary to remove the slug 33 located there.
[0050] The second reason why the piercing and riveting section 22 is not used to pierce the hole 32 here is that this self-piercing function is normally only used for metal sheet thickness of up to 2 mm. In the embodiment of FIG. 1 , however, the second component 30 is made of two metal sheets on top of one another which have a total thickness of more than 2 mm. It is, however, by no means problematic that the piercing and riveting section 22 is not self-piercing. There is instead even an advantage in this respect which can be seen from a comparison of the embodiments of FIGS. 1 and 2 .
[0051] The rounded drawing edge 34 of the piercing and riveting section namely serves to align the second component 30 with respect to the first component 14 . As a rule, not just one fastener device 10 is provided, but rather a second or a plurality of further fastener devices which are arranged at positions spaced from one another. These can then take over the task of aligning the two components 14 and 30 with respect to one another.
[0052] FIG. 2 shows the position after the alignment of the two components 14 and 30 relative to one another and, however, also shows a die 40 which is arranged beneath the first component 14 , and an upper die 42 which is arranged in the plunger of a setting head and is used to rivet the piercing and riveting section 22 to the second component 30 . The exact design of this die 42 is not described here as it is actually well-known due to the familiarity of the RSF elements. The corresponding method is additionally described in detail for the RSF nut element in German patent 36 10 675.
[0053] The joint between the two components 14 and 30 and the fastener device 10 arranged therebetween has the appearance shown in FIG. 3 after the riveting of the piercing and riveting section 22 to the second component 30 . It can be seen that the piercing and riveting section 22 has been formed into a peripheral rivet flange 44 by the pressing of the joint between the two dies 40 and 42 .
[0054] It can also be seen that the two components 14 and 30 now touch closely at two points, namely at points 46 and 48 . The structure formed in this way is now completed by the carrying out of welding at points 46 and 48 . Then a third component (not shown) can be screwed to the component assembly of FIG. 3 by means of a bolt, with the thread of the bolt being screwed into the thread cylinder 28 of the fastener device 10 .
[0055] The invention is further explained below by means of further embodiments, with identical parts being provided with the same reference numerals and these parts substantially only being described again if properties are of significance which differ from the properties of the corresponding parts in the embodiment in accordance with FIGS. 1 , 2 and 3 .
[0056] FIG. 4 shows a view partly sectioned in a longitudinal direction of a further fastener device 10 whose upper end is basically designed in accordance with the lower end of the fastener device 10 of the embodiment of FIG. 1 , but only with the difference that the upper end, like the whole fastener device 10 , is hollow and has a thread cylinder 28 . The lower end 12 of the fastener device of FIG. 4 is made in this example in accordance with an RSN nut element of the Profil company, i.e. corresponding to a nut element in accordance with European patent 0 539 739, so that the exact design of the corresponding features of shape is not described in detail here. The nut element-like design at the lower end 12 of the fastener device 10 of FIG. 4 is made with a somewhat larger diameter, i.e. substantially corresponding to the so-called RND nut elements of the company of Profil.
[0057] The joint of the lower end 12 of the fastener device 10 to the first component 14 is shown in FIG. 5 . It can be seen that the corresponding shaped sheet metal part has a conical collar 50 between the flange 52 at the lower end of the fastener device 12 and the riveting section 54 deformed by the riveting procedure, with this bent-around riveting section being planar with the lower side of the component 14 in this embodiment, in accordance with one of the advantages of the clamping hole method, which is particularly favorable during the bolting of further components to the lower side of the component 14 .
[0058] When carrying out the clamping hole method, the conical collar 50 is first set somewhat steeper and then pressed flatter during the joining process, whereby a high-quality joint connection is created. The noses providing security against rotation, which are not shown here, but which are present, ensure that no rotation of the fastening device 10 occurs with respect to the sheet metal part 14 when a screw is inserted.
[0059] FIG. 5 , however, also shows the joint between the upper end 18 of the fastener device 10 of FIG. 4 to the second component 30 . This joint is substantially identical in design to the design at the lower end 12 of FIG. 1 , but for one exception.
[0060] The sheet metal part 14 is pre-pierced during the carrying out of the clamping hole process in the lower region of the fastener device 10 . After this joint has been made, i.e., at the first lower end of the fastener device 10 , the second component 30 is then placed over the not yet deformed piercing and riveting section 22 of the fastener device 10 of FIG. 4 and subsequently turned over into a flange as shown in FIG. 5 . As the component 30 is pre-pierced here, no slug is created, unlike the design in the lower part of FIG. 1 . It would, however, easily be possible to utilize the self-piercing function of the piercing and riveting section 22 of the fastener device 10 of FIG. 1 , whereby then a slug would arise which would close the upper end 18 of the fastener device 10 of FIG. 5 . The slug can, however, be removed if desired via a plunger which is led through the hollow fastener device 10 .
[0061] The formation of both the first joint made by a forming technique in the region of the first component 14 and the second joint made by a forming technique in the region of the second component 30 takes place in both cases in a press. Use is made of the appropriate die and the appropriate pressing plunger which are described precisely in the relevant patent applications covering the different types of fastening so that these parts are not described further here.
[0062] FIG. 6 only shows that the fastener device 10 can also be attached to a component in the region of the lower end 12 comprising two layers of sheet metal 56 and 58 . The joint made by a forming technique in the region of the upper end 18 of the fastener device 10 can—if desired—also be made with two or more layers of sheet metal.
[0063] FIG. 7 now shows three fastener devices 10 designed in accordance with the fastener device 10 of FIG. 4 , but having three different lengths.
[0064] For illustration purposes, all three fastener devices 10 of FIG. 7 are inserted spaced from one another into different regions of the two components 14 and 30 , whereby a step-like design is created. While this design can easily be realized, it was chosen more to make clear the different lengths of the different fastener devices 10 .
[0065] It can be seen that for all three fastener devices 10 of FIG. 7 , the joints made by a forming technique to the respective components 14 or 30 are made at both ends 12 and 18 in exactly the same way as shown in FIG. 5 .
[0066] FIG. 7 , however, also shows how a third component 60 is fastened to the component assembly 62 of FIG. 7 , via three screws 64 here, with the head part 66 of each bolt 64 contacting the third component 60 and the shaft part 67 extending through the third component 60 , the first component 14 and partially through the fastener device 10 and the thread 68 of each bolt 64 being screwed into the thread cylinder 28 of the respective fastener device 10 .
[0067] As the thread cylinder 28 is spaced relatively far away from the first component 14 , relatively long screws, which can then be designed as waisted bolts, can be used for all three fastener devices 10 of FIG. 7 .
[0068] The fastener devices of FIGS. 4 , 5 , 6 and 7 have particular advantages for the intended application. On the one hand, the annular flange 52 ensures that each fastener device 10 is precisely at right angles to the first component 14 . The joint in the region of the first component is also capable of accepting shear and pressure torque statically and dynamically without problem thanks to the comparatively large diameter of the part 52 . The joint in the region of the deformed riveting section 54 serves, on the one hand, for security against press-out and, on the other hand, for rotational security of the fastener device 10 with respect to the first component 14 .
[0069] The riveting section 22 at the second end 18 of the fastener device 10 ensures a high-quality centering and positioning of the second component 30 with respect to the first component 14 when the second component 30 is being assembled with the first component 14 . The noses providing security against rotation in the shoulder region around the piercing and riveting section 22 increase the rotational security of the joint between the fastener device and the two components. In addition, the joint in the region of the end 18 is also capable of accepting shear and pressure forces. Furthermore, a good seal is achieved for both the joint to the first component 14 made by a forming technique and for the joint to the second component 30 made by a forming technique, which can be made liquid-tight without any problem and ensures a gas-tight joint with exact tolerances. Moreover, in this case—as also with every other joint addressed in this application—a sealing adhesive can also be used if absolute gas-tightness is required.
[0070] It is easy to understand that a dynamic tilting movement of the fastener device 10 with respect to the first component 14 can be excluded by the length of the fastener device 10 and of the other joints between the two components 14 and 30 so that the joint is capable of withstanding dynamic stresses without problem. The structure has a great strength so that it is particularly suitable for the attachment of other high stiffness components, for example the component 60 .
[0071] FIG. 8 shows a further embodiment in accordance with the invention of the fastener device 10 , with the lower end 12 being made in accordance with the upper end 18 of the fastener device 10 of FIG. 1 , i.e., in accordance with the RSF nut element of Profil. The upper end 18 of the one-piece fastener device 10 shown in FIG. 8 is, however, made as a blind-rivet sleeve 70 . The fastener device 10 has a tightening mandrel 72 having a shaft part 74 , a head part 76 and a position of fracture 78 . The lower region of the shaft part 74 is provided with cross-knurling 80 . The point of this design is to generate features of shape which avoid slippage when a drawing tool is applied. These features of shape 80 can also have any other shape which serves the given purpose.
[0072] It can be seen that the rivet sleeve 70 merges into a first shoulder 82 extending radially to the axial direction 31 of the fastener device 10 , with the transition taking place via a second annular shoulder 84 whose diameter is greater than the diameter of the blind-rivet sleeve 70 , but smaller than the outer diameter of the annular shoulder 82 .
[0073] The fastener device 10 of FIG. 8 is first inserted in a first sheet metal part 14 , with the design in the region of the lower end 12 of the fastener device 10 in FIG. 9 corresponding to the design of the corresponding lower end 12 of the fastener device 10 of FIG. 1 .
[0074] The second component 30 is also pre-pierced here and, as shown on the left-hand side of FIG. 9 , provided with a conical collar 90 which extends in a direction away from the first component 14 . The conical collar 90 bounds a hole 92 having a diameter slightly greater than the outer diameter of the annular shoulder 84 , but smaller than the outer diameter of the annular shoulder 82 .
[0075] When the mandrel 74 is tightened in the direction of arrow 94 (with a simultaneous pushing away of the component 14 in the opposite direction), the head part 76 of the mandrel deforms the blind-rivet sleeve 70 into an annular flange 96 and presses the conical annular collar 90 back flat again so that a design is created as shown at the top right in FIG. 9 . As soon as this position is reached, the shaft part 74 of the mandrel 72 breaks at the position of fracture 78 . The lower end of the shaft part 74 shown in FIG. 9 can then be removed. It can be seen, in particular from FIG. 8 , that the lower side of the head 76 of the mandrel 72 has a rounded undercut 98 in the region of the transition to the shaft part 74 . When the rivet sleeve 70 is being deformed, material of the rivet sleeve is also displaced into this rounded undercut. This leads to the head part 76 of the mandrel being held in the fastener device 10 with the shaft part in a force-transmitting and/or form-locked manner above the fracture position and cannot be lost. If, for some reason, the head part of the mandrel should be removed, for example to attain access to a female thread in the upper region of the fastener device 10 of FIG. 9 (not shown in FIG. 9 ), then this rounded undercut 98 can be omitted.
[0076] It can be seen that the fracture position 78 is above the thread cylinder 28 in the FIG. 9 embodiment so that the rest of the mandrel does not prevent the insertion of a screw into the thread cylinder 28 from below.
[0077] FIG. 10 shows a modified version of the lower end 12 of the fastener device 10 of FIG. 8 . The lower end is here made in correspondence with the lower end 12 of the fastener device 10 of FIGS. 4 and 5 , with FIG. 10 showing the embodiment before the attachment of the first component 14 and FIG. 11 the position after the attachment to the first component 14 .
[0078] FIG. 12 shows a version similar to FIG. 9 , but of a further modification of the fastener device 10 . In this case, the joint with the second component 30 is not made at the upper end of the fastener device 10 , but in a region 100 spaced from the first lower end, with the upper end 18 ′ of the fastener device 10 now protruding away from the side of the second component 30 remote from the first component 14 after the pulling up of the blind-rivet joint. This could, for example, be of advantage if the upper end 18 ′ were fitted with a further thread cylinder 102 so that another part could be screwed on here. For example, with the embodiment of FIG. 12 , the one end of a shock absorber could be screwed to the component 14 while utilizing the thread cylinder 28 , while the thread cylinder 102 serves the fastening of a brake line.
[0079] FIG. 13 shows a further embodiment in accordance with the invention of a fastener device 10 which has the already described features of shape of the SBF element in the region of its lower end 12 , but which is made hollow here with a thread cylinder 28 —as is also shown in the FIG. 4 embodiment.
[0080] FIG. 14 shows a possible attachment of the lower end 12 to a cup-like first component 14 . The upper end 18 of the fastener device 10 of FIG. 14 is then bonded to a second component 30 . The two components 14 and 30 are subsequently welded to one another at the positions 46 and 48 . A third component 60 is subsequently screwed to the component assembly comprising the components 14 and 30 by means of a bolt 64 , with the threaded part of the bolt 64 being screwed into the thread cylinder 28 of the fastener device 10 . The adhesive bonding to the second component 30 can optionally be omitted here.
[0081] FIG. 15 shows an embodiment very similar to the embodiment in accordance with FIG. 7 . Here, the fastener device 10 is made in three parts. It consists at its end 12 of an RND element 12 A from Profil, at its end 18 of an RSF or SBF element 18 A (realized in the case of the SBF element as a nut instead of a bolt element) and of a spacer tube 112 therebetween. The joint between the spacer tube 112 and the element 12 A at the lower end 12 and the element 18 A at the upper end 18 can be carried out, for example, by welding. The thread of the bolt 64 engages the thread cylinder in element 18 A at the end 18 of the fastener device 10 .
[0082] FIG. 15 shows how fastener devices 10 of different lengths can be generated by utilizing spacer tubes of different lengths, with no spacer tube at all being used with the fastener device 10 in the bottommost embodiment. The joint between the two elements 12 A, 18 A and the spacer tube 112 can also be made otherwise. For example, the elements and the spacer tube could be fastened to one another by an adhesive bond. This is easily sufficiently secure in some cases since all joints are loaded in compression when the screw 64 is tightened.
[0083] The embodiment in accordance with FIG. 16 is similar to that of FIG. 15 , except that here the spacer tube 112 is pressed (optionally adhered) into a cylindrical recess 116 of the element 12 A at the end 12 of the fastener device 10 , whereby a secure joint is ensured between the spacer tube 112 and the element. A corresponding joint would actually also be possible with the element at the end 18 . However, it may be better to omit an interengagement of the two parts here so that a more simple alignment of the two elements is possible when the screw is inserted. The joint between the element at the end 18 and the spacer tube 112 can, however, also be welded in the FIG. 16 embodiment.
[0084] In the bottommost embodiment of the fastener device in accordance with the invention of FIG. 16 , the end of the element 18 A engages with the end 18 of the fastener device directly into the cylindrical recess 116 of the element 12 A at the end 12 .
[0085] In FIG. 17 , the fastener device is made in two parts, with the lower end of the fastener device 10 being formed by the end 12 of the spacer tube 112 and this being received in a cup-like recess 115 in the first component 14 and being capable of being pressed in, bonded or welded there. The joint between the spacer tube 112 and the element at the other end 18 of the fastener device 10 is carried out such as described in connection with FIGS. 15 and 16 . In the bottommost embodiment of the fastener device 10 of FIG. 17 , the spacer tube 112 is an integral component of the element 18 A which is connected by a forming technique to the component 30 .
[0086] A three-part embodiment of the fastener device 10 is present in FIG. 18 . Two identical fastener elements 12 A, 18 A are used here in the form of RND nut elements from Profil, with a spacer tube 112 being arranged therebetween to make the three-part fastener element 10 . In these embodiments, the elements 12 A, 18 A each have a cylindrical part 122 which is pressed into a respective end of the spacer tube. The joints between the individual elements 12 A, 18 A and the spacer tube 112 can be selected freely, i.e., for example, with a fit as a force fit, by an adhesive bonding, as a welded joint or as a pinched joint.
[0087] FIG. 19 shows a similar embodiment to FIG. 18 , except that here the spacer tube 112 is provided with cylindrical recesses 123 at its two ends so that it is made with a thicker wall at its middle between the two elements than in the embodiment of FIG. 18 . The stability is increased even further in this way.
[0088] The embodiment in accordance with FIG. 20 is performed while utilizing shaped sheet metal parts 14 and 30 which each have cup-like recesses 115 corresponding to FIG. 17 . A multi-part fastener device 10 is also utilized here. It comprises an element 18 A made as an RND element and connected in a form-locked manner to the second component 30 . The second part of the fastener device 10 consists of a spacer tube 112 having cylindrical annular flanges 117 at its two ends which sit in form-filled manner in the respective cup-like recesses 115 . The joints between the ends of the spacer tube 112 and the respective recesses can be made freely, for example as a fit, a force fit or by means of a bond or weld.
[0089] FIG. 21 then shows an embodiment corresponding to the previous FIG. 19 , with, however, the two elements being pressed into the respective ends of the spacer tube 112 and this having ribs or grooves 119 extending in an axial direction which serve for rotational security. A radial pinched joint can also be made between the elements and the spacer tube.
[0090] FIG. 22 again shows an alternative, three-part embodiment of a fastener device, here while utilizing two circular elements 12 A, 18 A which each have a flange 130 having a first diameter and a cylindrical part 132 having a smaller diameter than the flange 130 . The cylindrical part 132 , which has a chamfer 134 at its end remote from the flange 130 , is inserted in the component 14 or 30 through a corresponding hole 136 or 138 respectively. The arrangement is made such that the two flanges 130 of the two elements are on opposite sides of the first and second components 14 and 30 , the ends 140 of the two elements face one another. The end 140 of the element 18 A is provided with a conical recess 141 which is intended as an insertion aid for the tip of a bolt. This type of insertion aid is particularly of importance when the inner diameter of the spacer tube 112 is much greater than the outer diameter of the bolt, as such a difference in diameter involves the risk of the bolt tilting which can be overcome by means of such an insertion aid, optionally with a corresponding design of the free end of the bolt, for example with a conical tip. Another possibility of overcoming this risk of tilting, which makes the insertion of the bolt more difficult or even impossible and could even lead to thread damage, is described below in connection with FIGS. 25A to D. Both the conical inserting aid and the corresponding centering sleeve in accordance with FIGS. 25A to D can be used in all other embodiments where there is a risk of tilting.
[0091] A spacer tube 112 having a peripheral annular nose 142 at its two ends is located between the two components 14 , 30 . The upper element has a thread cylinder 28 , the lower element a cylindrical bore 28 A whose diameter is somewhat greater than the outer diameter of the thread cylinder 28 . The arrangement is pressed together by pressure. During this pressure, the annular noses 142 displace material of the two components 14 , 30 so that the displaced material is formed into respective annular grooves 144 of the elements 12 A, 18 A, whereby a form-locked joint is created between the two components 14 and 30 and the respective elements 12 A and 18 A. The chamfers 134 make the slipping in of the respective elements into the spacer tube 112 more simple. The cylindrical region 132 has a diameter which is slightly greater than the inner diameter of the spacer tube 112 so that a force fit is created here.
[0092] When a third component 60 is attached to the first component 14 , a screw element 64 is inserted through the through bore 28 A of the first element 12 A and screwed together with the thread cylinder 28 of the second element 18 A. The screw connection provides additional security of the joint of the three elements to a fastener device 10 .
[0093] FIG. 23 basically shows the same arrangement as FIG. 22 , but it shows that the fastener element can here in inserted in bent regions of the respective sheet metal parts 14 or 30 .
[0094] FIG. 24 shows a one-piece fastener device 10 similar to FIG. 4 , with, however, the two ends of the fastener device being offset with respect to one another. Such an embodiment can sometimes be of help with special installations when particular space restrictions exist. It is also possible to equip the fastener device of FIG. 24 with two thread cylinders 28 , 102 , with, for example, the thread cylinder 28 at the lower end of the fastener device in FIG. 24 serving the attachment of a third component 60 , while the thread cylinder 102 at the upper end of the fastener device can be used for the attachment of an additional part, for example, a brake line fastener.
[0095] The drawings of FIGS. 25A to D, finally, show a possible method for the making of a joint in accordance with the invention.
[0096] FIG. 25A first shows a first sheet metal part 14 in a tool 149 having a centering mandrel 150 . The sheet metal part 14 has a recess U-shaped in cross-section in whose base region a first hollow element corresponding to the middle element 12 A of FIG. 18 is fastened by a forming technique. The formation comprising the sheet metal part 14 with the elements 12 A is placed over the centering mandrel 150 . The two lateral, horizontal regions 14 A and 14 B are situated on respective welding electrodes 152 and 154 respectively. A loose centering sleeve 156 , which is made, for example, of plastic and which can optionally be slit to save weight, is located on the centering mandrel above the element 12 A.
[0097] FIG. 25B shows the formation of FIG. 25A , with, however, the spacing tube 112 now being placed over the centering sleeve and being optionally capable of being pressed onto the cylindrical projection 158 of the element 12 A if a force fit is present. Alternatively thereto, for example, an adhesive bond or a joint having play could be present. The spacer tube 112 could, however, also be fastened to element 12 A by one of the methods given above before its attachment or be welded thereto or formed in a one-piece fashion therewith.
[0098] A second sheet metal part 30 is located above the sheet metal part 14 and is provided with a nut element 18 A in accordance with FIG. 18 , with the element 18 A already being riveted to the sheet metal part 30 . The assembly part consisting of the nut element 18 A and the sheet metal part 30 is now placed in a centered fashion over the sheet metal part 14 and the element 12 A with spacer tube 112 while utilizing the centering mandrel. The cylindrical projection 160 of the nut element 18 A is optionally pressed or bonded into the free end of the spacer tube or sunk therein with play. The two sheet metal parts are welded together by means of two further welding electrodes 162 , 164 .
[0099] FIG. 25 then shows the completed construction after removal from the tool 149 and after attachment of a component 60 by means of a bolt 64 . The centering sleeve 156 prevents the tilting of the bolt 64 during its insertion. Instead of first riveting the element 18 A to the sheet metal part 30 , the element 18 A could first be connected to the spacer tube and then riveted to the sheet metal part. The fastener device comprising the element 12 A, the spacer tube 112 , the centering sleeve 156 and the element 18 A could also be prefabricated as a unit, then riveted to the sheet metal part 18 or 30 and subsequently riveted to the respective other sheet metal part 30 or 18 either before or after its weld fastening to the sheet metal part 18 or 30 .
[0100] The components are preferably sheet metal parts, but can also be extruded parts or be made of another material, for example, of plastic.
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A first and second component joint includes using a fastener having a first end, and a flange having a diameter greater than a tubular barrel portion. A second end having a second tubular barrel portion merges into a shoulder of a flange part having a greater diameter than the barrel portion. The first tubular barrel portion is deformed radially outwardly sandwiching the first component between the flange and the first barrel portion. The second end of the fastener is introduced through a hole in the second component by applying the second component to the first component so the shoulder of the flanged part abuts the second component spacing the second component from the first component. The fastener device is fastened to the second component by deforming the second tubular barrel portion radially outwardly sandwiching the second component between the shoulder and the tubular barrel portion.
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SUMMARY OF THE INVENTION
The invention relates to a game for several players competing individually. It pertains to the buying and selling of commodities and to some extent can be regarded as educational.
The game involves the purchase of several commodities as required by the rolling of a particular die. Purchases proceed successively from player to player until all commodities have been purchased. The number of commodity units to be purchased is determined in this step and the players buy accordingly at the face price of each commodity.
The game proceeds by determining the market price of each commodity, by the spin of a wheel. Then three dice are thrown at a time by the players successively. One die is the command die, which directs the player to buy or sell a certain commodity, or to pay a tax or receive a certain amount from the Treasury as tax return. The selling can take place by auction. The second or commodity die determines the particular commodity involved in the transaction. The third die, called the quantity die, designates the number of units of that deal. If the tax or tax return commands come up on the command die, then the commodity die is ignored.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the game board showing a map of the world and circles on which disks are placed during the course of the game;
FIG. 2 is a face elevation of the spin wheel, known as the Fluke Wheel;
FIG. 3 is a top face view of the several disks which are placed on the game board and are color-coded as indicated;
FIG. 4 is a bottom view of one of the disks showing that each contains one character of the word "FLUKE!" and in this instance, a number;
FIG. 5 is a bracketed perspective view on an enlarged scale of each of the command die, the quantity die, and the commodity die;
FIG. 6 is a bracketed perspective view of the several playing units or pieces representing the commodities gold, silver, copper, oil, coffee and timber;
FIG. 7 is an illustration of the typical type of currency or monetary tender which may be employed in playing the game of this invention; and
FIG. 8 is an illustration of the typical form of a check which may be employed in playing the game of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
INTRODUCTION
The game is called "FLUKE!" and the object is to accumulate wealth from the sale of the several commodities. The player who has made the maximum amount of money at the end of the playing period is the winner. In the first instance, the players explore all over the world, as exemplified by the game board, for the different selected commodities. After acquiring the commodities, the players enter the world market with the aim of making money. Two people can play the game, but it is preferable that a greater number participate.
GAME BOARD, SPIN WHEEL AND PIECES USED IN GAME
A game board 10 has depicted the world on which are arranged thirty-six circles 11 in different areas where the commodities involved are obtainable. On each circle is a character 12, and in this instance, each character is from the word FLUKE!, the name of the game. The letters are arranged to read "FLUKE!" if read in a particular sequence, uniquely different for each set of six circles.
Initially thirty-six disks 14 of cardboard or any suitable material and of about the size of the circles 11 are placed randomly upon the circles 11. These disks are in sets of six. Each set is color-coded. As indicated in FIG. 3, one set "a" has its upper face colored black to represent the commodity oil. Set "b" is colored light brown to represent timber. Set "c" is colored dark brown to represent coffee. Set "d" is colored copper to represent copper. Set "e" is colored silver to represent silver. Set "f" is colored gold to represent gold. The underside of each disk 14 bears one character of the word "FLUKE!" and only three disks 14 of each set of six bear a number, which is 5, 3 or 2.
Commodity units or pieces used in the game are shown in FIG. 6. There are ten units for each commodity. These commodities are represented as follows: a small bullion-shaped block 16 for gold showing a face price of $1500; a coin-like disk 17 for silver with a face price of $1000; a barrel-like cylinder 18 for oil bearing a face price of $800; a small rectangular block 19 for copper bearing the face price of $600; a small bag 20 formed of a transparent plastic material containing a few dark grains to represent coffee beans bearing a face price of $400; and a cylinder 21 for timber bearing the face price of $200 .
A spin wheel 22 or "FLUKE WHEEL", as it is called, is shown in FIG. 2, and has a central axle 23 securing it to a stationary back plate 24. For convenience, the plate 24 may be vertically inclined so as to be readily viewed by all players. On the wheel 22 are six equidistantly spaced labels 25 near the rim bearing the names and prices respectively of the above commodities. Each label 25 has a center pivot 26. Thus, if the plate 24 is upright, the labels 25 will always orient themselves in the horizontal position, thus enabling players to read them easily. Adjacent to each label a color-coded circle designated by a' or b' etc. in FIG. 2 is drawn on the wheel 22 to symbolize the particular commodity listed in that label.
The back plate 24 outside of the wheel 22 is separated into six equal sections 27 bearing in sequence the numerals 1, 2, 1/2, 2, 3 and 2 referred to as "Price Indices". As will hereinafter appear, when the wheel 22 comes to rest after being spun, the market price of any commodity adjacent to a particular section is obtained by multiplying the face price of the commodity by the Price Index shown on the wheel 22.
Three dice as indicated in FIG. 5 are used. One die 28 is called the "COMMAND DIE" and has on its faces the word "BUY" on its two faces, the word "SELL" on other two faces and "TAX" and "TAX RETURN" on each of the remaining two faces. Thus, upon the throw of this die the player must buy, sell, pay tax or will receive a refund from the Treasury.
A second die 29 is called the "QUANTITY DIE" having the indicia "1 UNIT", "2 UNITS", . . . all the way through "UNITS" marked respectively on each of its faces.
The third die 30 is called the "COMMODITY DIE" and has the colors gold, silver, black, light brown, copper and dark brown on the respective side to designate gold, silver, oil, timber, copper and coffee, the commodities around which the game centers.
All the buying and selling of commodities requires a monetary tender, which is issued by the World Government. The play money is available in the denominations of $10,000, $5,000, $1,000, $500, $100 and $50 as illustrated in FIG. 7.
In case one falls short of cash while under the command of the die to buy any commodity or to pay tax, one may write a check in the required amount to another player or the Treasury. FIG. 8 illustrates a sample check which may be called the "FLUKECHECK".
A tabulated card, called "PRICE CARD", is provided to all the players for their convenience. It shows the face prices of all commodities; their market prices corresponding to all price indices; and the total sum to be paid or received depending on the number of units bought or sold at that market price.
START OF GAME
At the outset, the closing time of the game is decided by the players. A Treasurer is then selected by the roll of the Quantity Die 29 with each player successively taking a turn in a clockwise direction. The player rolling the highest number becomes the Treasurer who plays the game as others and also runs the Treasury, for which he receives a one-time salary of $5,000 at the beginning of the game. Each player is given a starting capital of $25,000 in the form of play money, a check book and a price card.
All of the thirty-six disks 14 are placed randomly on the circles 11 of the game board 10 with the colored sides up. The play then starts by the Treasurer rolling the commodity die 30 alone. At this time the other dice are not used. Let us assume that on the roll, the color or indicia gold appears on the top face of the die. The Treasurer then picks any gold colored disk from the game board and examines its under or rear face. If there is no number on the disk, it means the player did not find anything in that area of the world. In that case, he passes the die to the next player. If, however, a player does find a number on the disk, he must buy that many units of the same commodity, in this instance gold, at face price. For example, if the disk has a number 5, the player is authorized and must buy five units 16 of gold at the face price of $1,500 per unit. He, therefore, pays $7,500 to the Treasury and receives five units of gold. He should also examine the letter on the disk and that on the circle. Should they match, he is entitled to purchase those units at half price. However, if such a match occurs on a numberless disk, it is useless. After purchasing the commodity, the player keeps the disk in front of him. The die is passed to the next player and the buying of commodities continues player by player until all the units of all the commodities are bought and there are no more disks on the board. The board is then put aside and is not again used in the game.
At this point, all players are to examine the letters (including the exclamation mark) on their disks in an effort to form one or more separate words from these characters. It is to be noted that the exclamation mark can be used as any letter of the alphabet to form a word. For every word constructed, the player gets a reward of $3000 from the Treasury. There is a special prize of $10,000 for forming the word "FLUKE!". The use of the disks is now over, so they may be returned to the Treasury.
THE SECOND PROCEDURE
The players now possess the various commodities and are prepared to wheel and deal. This takes place as follows. The Treasurer spins the Fluke Wheel 22 for establishing the market prices. For this purpose, the various commodities on the wheel should line up with one of the six sections 27 on the back plate 24-1, 2, 1/2, 2, 3, and 2. After every two rounds of play, the wheel 22 is spun again. For example, the market price of gold unit 16 from the Fluke Wheel 22, in position of FIG. 2, is $1500 (the face price of gold) multiplied by 2 (the Price Index) or $3000 per unit 16. Thus, the market prices of oil unit and timber unit would be $1600 and $400, respectively.
Copper units 19 have a market price of $1800 but silver units 17 would have a market price of $500 (one-half the face price of $1000).
THIRD PROCEDURE
BUY
The game is played in the clockwise direction. The player next to the Treasurer starts by rolling all the three dice. Let us assume his throw results in the Command Die 28 showing BUY, the Commodity Die 30 showing gold color representing gold and the Quantity Die 29 showing 4 UNITS. This means that he is required to buy from the next player or players 4 units of gold at the then prevailing market price. He buys these four units of gold from the next player whoever has them. Should the next player have only three units of gold, then the buyer buys those and goes further to the next player in line possessing at least one unit of gold. These players must sell to the buyer. In this instance, the buyer pays a total of $12,000 for the four units of gold, as dictated by the Fluke Wheel. See FIG. 2. If a player is short of cash, when required to buy, he must sell all his commodities by auction as explained under item "SELL" below. If even after doing so, he is still short of cash, then he may write checks to others in order to meet the balance of his financial obligations. If a buyer wants to participate in an auction in order to buy commodities, his bids must not exceed the total cash he has. The Treasury fines $500 for such an unauthorized bid and the auction goes on without the disqualified buyer.
SELL
A player must sell, if the Command Die 28 falls with the "SELL" side showing up. The other two dice indicate the commodity and the number of units of that commodity to be sold. If the Price Index is 1/2 or 1, the player must sell that commodity at that market price to the next player and the latter must buy it. No auctioning is allowed in this case. If, however, the Price Index is 2 or 3 the player required to sell must auction that commodity. This auction is open to all other players and no bidding is allowed below the market price. If nobody bids, the player next to the seller must buy those units from him at the market price. As mentioned above, players' bids cannot exceed the cash that they have and NO checks are allowed in auction.
TAX
In case the roll of the three dice results in the Command Die 28 showing TAX and the Quanity Die 29 shows 4 UNITS, a payment must be made to the Treasury of 4 times 1000 or $4000. The Commodity Die 30 is not considered in this case. Should 6 UNITS appear on the Quantity Die, then $6000 must be paid. In other words, the number of units indicated by the Quantity Die multiplied by 1000 determines the amount to be paid.
TAX RETURN
In the event of the Command Die 28 showing "TAX RETURN", the player receives from the Treasury an amount equal to the number of units on the Quantity Die multiplied by 1000. For example, a throw of 5 UNITS on the Quanity Die 29 in conjunction with the "TAX RETURN" command entitles a player to receive $5000.
The above Third Procedure continues from player to player until the predetermined time of play has expired.
FINAL PROCEDURE (called The "GRAND FLUKE")
At the time of closing the game, the Treasurer gives the Fluke Wheel 22 a final spin for determining the final market prices of the several commodities. As noted above, the market price is obtained by multiplying the face price of the commodity appearing on the wheel by the figure appearing in the adjacent section, namely the Price Index 27. The Treasury then buys back from all players all of their commodities at the final market price. All players count their money and report the amount of cash to the Treasurer and present to him the checks they have received. He then substracts the amount written in the checks from the total cash of the writer of the check and adds it to the cash of the receiver of the check. In addition, the Treasury charges a handling fee of $500 per check to the writer of the checks. The player who has the most money, is the winner.
It should be mentioned that the auction specified under "Sell" in the Third Procedure, may be omitted when playing with children, so as to somewhat simplify the game. In such an event, the player sells his commodity to the next adjacent player.
Although I have described the preferred form of the invention, it is to be understood that changes in details of procedure and devices employed may be made without departing from the invention, especially as defined in the appended claims.
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A game of commodity trading having a world map with a plurality of circles and disks placed on the circles corresponding to different commodities. A command die, a quantity die, a commodity die and a market price setting spinner are used in play of the game. The players start by rolling the commodity die, picking a corresponding disk and buying a corresponding commodity until all disks are gone. The disks have letters on them and the players form words from the disks. The market price spinner is then used to set the market price for the commodities. The players then throw the three dice and follow the dice directions. The winner is the player with the most money at the end of the predetermined time.
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CROSS REFERENCE TO RELATED CASES
This application is related in subject matter to Ser. No. 10/789,975, filed Feb. 27, 2004, which application is hereby incorporated herein by reference in its entirety.
COPYRIGHT NOTICE/PERMISSION
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to the software and data as described below and in the drawings referred to herein: Copyright 2005, Cyberscan Technology, Inc., All Rights Reserved.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of regulated pay computer-controlled games, either games of skills or games of chance, and more particularly to the field of certification of the related regulated software.
2. Description of the Prior Art and Related Information
Pay entertainment and gaming systems of the prior art, either of the cash-in or the cash-less type, are seriously limited due to the technical choices made in order to comply with gaming regulatory requirements. Regulators are mainly concerned with funds that may be illegally acquired by individuals as well as with funds that may not be acquired by legitimate winners as a result of flaws, cheating and/or stealing. Game regulators are reluctant to accept state-of-the-art operating systems, multimedia and Internet technologies because of security concerns and tend to favor antiquated technology based upon secrecy rather that “open” state-of-the-art technology. A “Request/Authorize” method for downloadable games has been proposed by another company (IGT's Secure Virtual Network in a Gaming Environment—Publication US2002/0116615 A1) but the method disclosed therein does not cover how to ensure that only certified authorized components may execute.
Gaming certification labs (such as Gaming Laboratories International, Inc. (GLI), for example) require game software manufacturers to provide a complete software compilation environment (software, hardware and tools) such that source code may be compiled to produce the complete executable binary code and to test it. In addition, each revision change to the source code (and/or related file) must be done via a formal contractual submission (including source code files, related files and traceability paperwork) subjected to a stringent procedure in order for the gaming laboratory to identify and track the exact lines of changed source codes in the re-testing process. Due to the broad diversity of software executable environments, software development environments and legacy source code found in the gaming industry (gaming machine microprocessors, operating systems, languages, servers, network topologies, graphics studios, development tools, testing tools, emulators, etc. . . . ), management of source code by the gaming labs is essentially manual, lengthy, error prone and costly.
Source Code Control Systems (SCCS) such as MS-SourceSafe, SourceGear-Vault (www.sourcegear.com), NXN (www.nxn-software.com) and more particularly the not-yet released Microsoft Visual Studio 2005 Team System (http://msdn.microsoft.com/vstudio/teamsystem) provide means for developing and managing large scale software projects involving numerous geographically dispersed developers and subcontractors. Indeed managing source code with a SCCS requires specialized skills and training, and as each game supplier typically uses a different commercial SCCS or internally developed SCCS, it is beyond the undertaking of a game certification laboratory to have their engineering stall trained in a plurality of SCCS.
In order to successfully leverage on the new emerging downloadable game paradigm (such as disclosed in commonly owned and co-pending application serial number 10/789,975 filed on Feb. 27, 2004 and entitled Dynamic Configuration of a Gaming System, the entire specification of which is included herewith by reference), there is a need to produce a significant number of regulatory certified games and game variants. The game certification labs have not yet anticipated the complexity of the downloadable game paradigm and have not yet issued precise directives relating to the manner in which game software suppliers are to supply the substantial number of source code files and related filed in a rigorously controlled manner. The complexity of managing source code in the certification life cycle of downloadable game software is such that if not satisfactorily addressed, manufacturers may suffer significant delays and cost in having their software certified—which can already take several years, thereby stifling innovation and increasing costs to the gaming industry. A procedure that may be applied for producing certified downloadable game software is described in the above-referenced Ser. No. 10/789,975 application at FIGS. 11-13 ). The very first step in generating certified games according to this procedure is to initialize a new submission”. In this first step, new source code is transferred from the manufacturer's software development environment into the game certification laboratory integrated certification environment (ICE). Often, this first step is lengthy, painstaking and error prone.
From the foregoing, therefore, it may be appreciated that new and improved methods and systems for submitting new source code from the manufacturer's software development environment to the game certification laboratory are needed.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide universal methods and systems for selecting, installing and uninstalling source code (and associated files) in a rigorously controlled manner, to enable game certification labs to certify large numbers of downloadable game software components. The method is not dependant upon any particular operating system, the language and/or the SCCS used by the certification lab. The methods and systems described herein are particularly adapted for the certification of numerous variants of games necessary for successfully implementing the dynamic casino floor paradigm across different jurisdictions.
For each contractual submission, a precisely identified file (hereafter called an installable submission package) that packages all of the source code, necessary related files and directives necessary for certification may be provided to the gaming certification lab. A packager utility may be used within the game developer's environment to enable selecting the source code to be certified and all of the necessary related files, as well as to enable compilation of installation directives, for example. Thereafter, the source code, related files and the installation directives, for example, may be combined in a single installable submission package file. The installable submission package file name identifier may reflect the certification process thread and stage, that is, may denote the customer, the applicable regulation, initial submission, bug fix, regulatory variant, retirement, etc. The file name identifier may advantageously be or include a text string comprising the relevant explicit codes and/or a GUI (Global Unique Identifier) associated to the applicable certification process details. An installer utility may allow the game certification laboratory to unpack the package provided by the game developer and to execute any included directives (such as, for example, installation, updating or uninstalling of source code and any associated files). In the case of an update, the old source code (and related files) may be advantageously cached in a structured manner such that a given update may be undone, if requested.
The installer utility may allow the target integrated software environment such as MS-Visual Studio to be adapted to cooperate for installing, updating and uninstalling the provided source code and related files in the installable submission package provided to the game certification laboratory.
Still further embodiments of the invention enable the certification authority to bind the certificates to the tested software components.
Embodiments of the present invention leverage the technology described in commonly assigned U.S. patent application filing 60/393,892 entitled—“Secure Game Download” in which code signing and Software Restriction Policy enable executing authorized game software. Code signing and Software Restriction Policy (SRP) technologies are available in Microsoft Windows XP, Windows 2000 and Windows 2003, Embedded Windows XP as well as in future Windows versions (as of this writing, the next version is code-named “Longhorn” and/or “Vista”) to ensure that only executable software components from a trusted publisher, let's say “Microsoft”, are allowed to run. Code signing and Software Restriction Policy technology are applied to executable components such as *.exe, *.dll, *.ocx, *.vbs, *.msi, *.cab, etc. In addition, Software Installation Policy (SIP) ensures that software components are installed in a controlled fashion. Embodiments of the present invention extend the use of code signing, Software Restriction Policy and Software Installation Policy to individual software components that are allowed to execute in a network connected gaming system by associating a distinct code-signing certificate to each executable software component. Each executable software component version (usually comprising major version, minor version, revision and build) may have a unique certificate. A distinct certificate may be created for each software component version and the two entities (the compiled code and the certificate) may be bound together by a code signing operation, herein called “signcode.exe”.
Code signed software components may be packaged together with non-signed software components (if any) into an installation package, such as (but not limited to) MSI Microsoft installation package (MSI=Microsoft Software Installation). An MSI package is an executable component that in turn receives a distinct certificate bound to its content by a code signing operation. Only the software component version that has successfully passed the regulatory certification process may be allowed to run by enforcing an unrestricted policy to the associated certificate.
The manufacturer's game software components comprising the source code, the associated data and control files as well as each component's location path within the manufacturer's development environment may be packaged by the manufacturer's deployment author into an .MSI or equivalent installation package that receives a unique identifier and a versioning number corresponding to the submission number and that may be code signed with a predetermined PKI certificate issued by a trusted certificate issuing authority. The game certification laboratory receiving the installation package may then execute the installation after verifying the validity of the PKI certificate in order to unpack the game software components in the game certification laboratory's software development environment at the same location paths as the supplier's development environment, or at locations manually entered during the installation process. The laboratory standard Windows “Add/Remove Program” utility shows the submission number and/or other identifications or notes of the installed source code. Source code patch sequencing may be carried out in the same manner using a version of an installer that supports patch sequencing, e.g. “Service Pack”, “Quick Fix”, “Engineering Fixes”, etc., the manufacturer's deployment author being responsible to embed the related patch sequencing control instructions within the package. Microsoft code developers may create a patch installation package by generating a patch creation file using the Msimsp.exe service. The laboratory standard Windows “Add/Remove Program” utility may show the submission number and/or other identifications or notes of the installed source code patch. Patch sequencing may allow smart application of patches such as but not limited to targeting, multi-targeting, multi-family, scoping, conditionality, chaining, superseding, forcing removal of prior patches, reverting of changes, and controlling life of source code patches. Game source code changes may then be examined by the game certification laboratory in the context of the structured patch sequencing information provided and be judiciously compiled.
Once the certification is completed, the game software source code and related files including the files derived during the code compilation process may be uninstalled by the laboratory by executing the uninstall command associated to the installed package. In the same manner, a predetermined source code patch may be installed or uninstalled from the game certification laboratory software development environment.
Installation standard actions and/or “custom actions” may be embedded by the manufacturer's deployment author into the installation package such as to carry out various auxiliary automated operations prior, during or after the installation of the source code and related files. In particular, the custom actions may be used for removing all files derived during the compilation and testing of the game software from the laboratory software development environment during the source code uninstalling. When the packages are code signed, the installing utility software (i.e. Microsoft msiexec.exe version 3.0 and later) being part of the trusted computing base then the action scripts are part of the trusted computing base and may be trusted during the installing and uninstalling of the source code and related files.
The packages containing the original source code and the source code patches may be code signed such as to provide persistent proof of origin which may be verified at any time. The method is generic and may be implemented under any operating system such Microsoft Windows, Linux, Unix and Apple Mac OS without the game certification laboratory having to learn a complex source code configuration management software.
Also, RM (Rights Management) technology offered with Microsoft Office 2003, with the associated RM services and SDK (Software Development Kit) may be used to ensure that only authorized data files may be accessed, viewed, copied or modified.
Accordingly, an embodiment of the present invention is a computer-implemented method for managing game source code for submission to a game certification laboratory. Such a method may include steps of selecting, in a first environment, the game source code and related files to be submitted to the game certification laboratory; packaging the selected source code and the related files into an installation package, and providing the installation package to the game certification laboratory for installation in a second environment.
According to further embodiments, the packaging step may include a full location path of the selected source code and related files. The related files may include one or more of: compiling directives, make directives, build directives, Microsoft Visual Studio Project directives, MS Visual Studio Solution directives, Microsoft MSBuild directives Visual, Studio automation scripts, compiled source code code-signing directives and target deployment directives, for example. The related files may include one or more of: data files, configuration files, XML configuration files, game media assets, video assets, test utilities, command scripts, policy scripts, target system policy enforcement scripts and target system execution restriction policy directives, for example. The installation package may be code signed with a PKI certificate issued by a trusted certificate authority. The installation package may contain installation custom actions, and such custom actions may be trusted when the package is code signed. The installation package may contain installation custom actions that are operative to perform automation operations in the second environment during package installation and/or un-installation. The second environment may be within the game certification laboratory and the method further may include a step of executing the installation package to unpack and install the selected source code and the related files into the second environment within the game certification laboratory. The first environment may include an integrated software development environment (IDE). The integrated software development environment may include MS-Visual Studio, for example. The second environment may include an integrated software development environment (IDE), for example. The integrated software development environment may include MS-Visual Studio, for example. The installation package in the providing step may be a Microsoft Installer Package (MSI), for example. The packaging step may include a step of code signing the installation package, and the code signing step may include a step of obtaining a distinct PKI certificate. The method may also include steps of configuring certificate rule policies to enable execution of the code signed installation package in the game certification laboratory, and configuring enforcement of the certificate rule policies. The packaging step may include embedding within the installation package attributes one or more of: a global unique identifier (GUID), a package file name identifier, a manufacturer identifier, a customer identifier, an applicable regulation identifier, a submission identifier, a part number identifier, a version identifier, a patch sequence identifier, and a regulatory variant identifier, for example. The game certification laboratory may be configured to check the identification details of the installed source code by viewing an “Add or Remove Programs” utility, including the installed source code patches when a “Show Updates” option is selected. The method may also include a step of removing installed source code from the second environment by selecting a corresponding “Remove” button in an “Add or Remove Programs” utility. The method may also include a step of removing an installed source code update or patch sequence from the second environment by selecting a “Show Updates” option and by selecting a remove button in an “Add or Remove Programs” utility. The present computer-implemented method may also include a step of removing source code, a source code update or a patch sequence from the second environment by selecting a corresponding option in an installer console program having a format “msiexec.dll/x {package}”, for example. The installation package may contain shortcut definitions for adding shortcuts in the second environment during the package installation for automating the source code certification process. The providing step may include providing the installation package in one of a CD-ROM, a movable media, an encrypted movable media, an email, an encrypted email, via VPN, and via encrypted Internet download, to name but a few possibilities. The source code of the second environment may be maintained synchronized with the source code of the first environment via the submission of the installation package. The source code and the related files of the second environment may be maintained synchronized with the source code and the related files of the first environment via the submission of the installation package. The certificate may be generated by the certificate authority under control of the manufacturer, the game certification lab, a game regulatory organization, a trusted third party and/or VeriSign, for example.
According to another embodiment thereof, the present invention is a machine-readable medium having data stored thereon representing sequences of instructions which, when executed by a computer, causes the computer to carry out a method of managing game source code and related files for submission to game certification laboratory, by carrying out steps of: selecting, in a first environment, the game source code and related files to be submitted to the game certification laboratory; packaging the selected source code and the related files into an installation package, and providing the installation package to the game certification laboratory for installation in a second environment.
The packaging step may include a full location path of the selected source code and related files. The related files may include compiling directives, make directives, build directives, Microsoft Visual Studio Project directives, MS Visual Studio Solution directives, Microsoft MSBuild directives Visual, Studio automation scripts, compiled source code code-signing directives and target deployment directives, for example. The related files may include, for example, data files, configuration files, XML configuration files, game media assets, video assets, test utilities, command scripts, policy scripts, target system policy enforcement scripts and/or target system execution restriction policy directives, for example. The installation package may be code signed with a PKI certificate issued by a trusted certificate authority. The installation package may contain installation custom actions, and such custom actions are trusted when the package may be code signed. The installation package may contain installation custom actions that are operative to perform automation operations in the second environment during package installation and/or un-installation. The second environment may be within the game certification laboratory and the method further may include a step of executing the installation package to unpack and install the selected source code and the related files into the second environment within the game certification laboratory. The first and/or second environment may include an integrated software development environment (IDE). The integrated software development environment may include MS-Visual Studio. The installation package in the providing step may include a Microsoft Installer Package (MSI). The packaging step may include a step of code signing the installation package, and the code signing step may include a step of obtaining a distinct PKI certificate. Steps may be carried out to configure certificate rule policies to enable execution of the code signed installation package in the game certification laboratory, and configure enforcement of the certificate rule policies. The packaging step may include embedding within the installation package attributes of at least one of a global unique identifier (GUID), a package file name identifier, a manufacturer identifier, a customer identifier, an applicable regulation identifier, a submission identifier, a part number identifier, a version identifier, a patch sequence identifier, and a regulatory variant identifier. The game certification laboratory may be configured to check the identification details of the installed source code by viewing an “Add or Remove Programs” utility, including the installed source code patches when a “Show Updates” option is selected. A step may be carried out to remove installed source code from the second environment by selecting a corresponding “Remove” button in an “Add or Remove Programs” utility. A step may also be carried out to remove an installed source code update or patch sequence from the second environment by selecting a “Show Updates” option and by selecting a remove button in an “Add or Remove Programs” utility. A step may also be carried out to remove source code, a source code update or a patch sequence from the second environment by selecting a corresponding option in an installer console program having a format “msiexec.dll/x {package}”, for example. The installation package may contain shortcut definitions for adding shortcuts in the second environment during the package installation for automating the source code certification process. The providing step may include providing the installation package in one of a CD-ROM, a movable media, an encrypted movable media, an email, an encrypted email, via VPN, and via encrypted Internet download, to name but a few possibilities. The source code of the second environment may be maintained synchronized with the source code of the first environment via the submission of the installation package. The source code and the related files of the second environment may be maintained synchronized with the source code and the related files of the first environment via the submission of the installation package. The certificate may be generated by the certificate authority under control of manufacturer, the game certification lab, a game regulatory organization, a trusted third party, and/or VeriSign, for example.
According to yet another embodiment thereof, the present invention is an automated platform to enable regulatory certification of game software components that includes a reference platform representative of a target network of gaming systems and comprising a software-building environment located at a premise of a manufacturer of the game software components; a certification platform located at a regulatory certification authority, the certification platform being substantially identical to the reference platform, and installation package generating means for generating at least one installation package that may include the game software components for which the regulatory certification is sought.
The installation package may include a full location path of the game software components. The related files may include compiling directives, make directives, build directives, Microsoft Visual Studio Project directives, MS Visual Studio Solution directives, Microsoft MSBuild directives Visual, Studio automation scripts, compiled source code code-signing directives and/or target deployment directives, for example. The related files may include one or more of data files, configuration files, XML configuration files, game media assets, video assets, test utilities, command scripts, policy scripts, target system policy enforcement scripts and target system execution restriction policy directives, for example. The installation package may be code signed with a PKI certificate issued by a trusted certificate authority. The installation package may contain installation custom actions, and such custom actions may be trusted when the package may be code signed. The installation package may contain installation custom actions for performing automation operations in the certification platform during at least one of package installation and un-installation. The installation package may be configured to be executed to unpack and install the game software components within the certification platform. The software building environment may include an integrated software development environment (IDE), such as MS-Visual Studio, for example. The certification platform may also include an integrated software development environment (IDE), such as MS-Visual Studio, for example. The installation package may include a Microsoft Installer Package (MSI), and the installation package may be code signed. The code signed installation package may include a distinct PKI certificate. The automated platform may be further configured to configure certificate rule policies to enable execution of the code signed installation package in the certification platform, and to configure enforcement of the certificate rule policies. The installation package may include attributes of one or more of a global unique identifier (GUID), a package file name identifier, a manufacturer identifier, a customer identifier, an applicable regulation identifier, a submission identifier, a part number identifier, a version identifier, a patch sequence identifier, and/or a regulatory variant identifier, for example. The installation package may be configured such that the certification platform is able to check the identification details of the software components by viewing the “Add or Remove Programs” utility, including any installed source code patches when the “Show Updates” option is selected. The installation package may be configured such that the certification platform is able to remove the software components from by selecting a “Remove” button in a “Add or Remove Programs” utility. The installation package may be configured such that the certification platform, when a “Show Updates” option is selected, is able to remove the software components by selecting a “Remove” button in an “Add or Remove Programs” utility. The software components may include a source code, source code update or patch sequence and the installation package may be configured such that the certification platform is able to remove the source code, source code update or patch sequence by selecting an option in an installer console program having a format “msiexec.dll/x {package}”, for example. The installation package may contain shortcut definitions for adding shortcuts in the certification platform during the package installation for automating the source code certification process. The providing step may include providing the installation package in one of a CD-ROM, a movable media, an encrypted movable media, an email, an encrypted email, via VPN, and via encrypted Internet download. The software components may include a source code and the software components of the certification platform may be maintained synchronized with the source code of the software-building environment via the submission of the installation package. The software components of the certification platform may be maintained synchronized with the software components of the software-building environment via the submission of the installation package. The certificate may be generated by the certificate authority under control of the manufacturer of the software components, of a game certification laboratory, of the regulatory certification authority, of a trusted third party and/or of VeriSign, for example.
According to still another embodiment thereof, the present invention is a computer-implemented method for synchronizing game source code and related files between a software development environment of a game certification laboratory and a software development environment of a game manufacturer. The method may include steps of selecting, in the game manufacturer's software development environment, the source code and related files to be submitted to the game certification laboratory; packaging the selected source code and the related files into an installation package, and providing the installation package to the game certification laboratory for installation in the software development environment of the game certification laboratory.
The packaging step may include a full location path of the selected source code and related files. The related files may include compiling directives, make directives, build directives, Microsoft Visual Studio Project directives, MS Visual Studio Solution directives, Microsoft MSBuild directives Visual, Studio automation scripts, compiled source code code-signing directives and/or target deployment directives, for example. The related files may include, for example, data files, configuration files, XML configuration files, game media assets, video assets, test utilities, command scripts, policy scripts, target system policy enforcement scripts and target system execution restriction policy directives. The installation package may be code signed with a PKI certificate issued by a trusted certificate authority. The installation package may contain installation custom actions, and such custom actions may be trusted when the package may be code signed. The installation package may contain installation custom actions that are operative to perform automation operations in the software development environment of the game certification laboratory during package installation and/or un-installation. The method may also include a step of executing the installation package to unpack and install the selected source code and the related files into the software development environment of the game certification laboratory. The software development environment of the game manufacturer may include an integrated software development environment (IDE), for example. The integrated software development environment of the game manufacturer may include MS-Visual Studio, for example. The software development environment of the game certification laboratory may include an integrated software development environment (IDE), for example. The integrated software development environment of the game certification laboratory may include MS-Visual Studio, for example. The installation package in the providing step may include a Microsoft Installer Package (MSI), for example. The packaging step may include a step of code signing the installation package and the code signing step may include a step of obtaining a distinct PKI certificate. The method may also include steps of: configuring certificate rule policies to enable execution of the code signed installation package in the game certification laboratory, and configuring enforcement of the certificate rule policies. The packaging step may include embedding within the installation package attributes one or more of a global unique identifier (GUID), a package file name identifier, a manufacturer identifier, a customer identifier, an applicable regulation identifier, a submission identifier, a part number identifier, a version identifier, a patch sequence identifier, and a regulatory variant identifier, for example. The game certification laboratory may be configured to check the identification details of the installed source code by viewing an “Add or Remove Programs” utility, including the installed source code patches when a “Show Updates” option is selected. The method may also include a step of removing installed source code from the software development environment of the game certification laboratory by selecting a corresponding “Remove” button in an “Add or Remove Programs” utility. The method may also include a step of removing an installed source code update or patch sequence from the software development environment of the game certification laboratory by selecting a “Show Updates” option and by selecting a remove button in an “Add or Remove Programs” utility. The method may also include a step of removing source code, a source code update or a patch sequence from the software development environment of the game certification laboratory by selecting a corresponding option in an installer console program having a format “msiexec.dll/x {package}”, for example. The installation package may contain shortcut definitions for adding shortcuts in the software development environment of the game certification laboratory during the package installation for automating the source code certification process. The providing step may include providing the installation package in one of a CD-ROM, a movable media, an encrypted movable media, an email, an encrypted email, via VPN, and via encrypted Internet download, for example. The source code of the software development environment of the game certification laboratory may be maintained synchronized with the source code of the software development environment of the game manufacturer via the submission of the installation package. The source code and the related files of the second environment are maintained synchronized with the source code and the related files of the first environment via the submission of the installation package. The certificate may be generated by the certificate authority under control of, for example, the manufacturer, the game certification lab, a game regulatory organization, a trusted third party, and VeriSign.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the intrinsic information that uniquely identifies each executable software component, according to an embodiment of the present invention.
FIG. 2 illustrates the information uniquely identifying each executable software component being made available into the Windows Event Log upon execution of the software component, according to an embodiment of the present invention.
FIG. 3 illustrates the information (test certificate indicator, project/product code, type of executable code, part number, major/minor/build/version, game certification laboratory identifier, friendly name) uniquely identifying each executable software component being used to generate the “Subject Name” (or “Issued to” field, or “CommonName” field) of the individual PKI certificate associated to each executable software component, according to an embodiment of the present invention.
FIG. 4 illustrates the information that may be entered in the Extended Attributes of a PKI certificate, according to an embodiment of the present invention.
FIG. 5 illustrates the information that may be obtained using the Trusted Inventory tool, according to an embodiment of the present invention.
FIG. 6 illustrates the information that may be entered to configure a type-certificate Software Restriction Policy rule, according to an embodiment of the present invention. A Software Restriction Policy (SRP) is configured using the Group Policy Object Editor.
FIG. 7 illustrates the policies that are associated to the active directory container used to configure the gaming machines, according to an embodiment of the present invention.
FIG. 8 illustrates an exemplary cycle from the moment a game is being created until it is first executed on a gaming terminal, according to an embodiment of the present invention.
FIG. 9 illustrates the global verification process performed by the terminal in order to check that no unauthorized file may execute or may affect game outcome, according to an embodiment of the present invention.
FIG. 10 illustrates the configuration of the three parties involved in a new game cycle detailed at FIG. 8 , according to an embodiment of the present invention.
FIG. 11 illustrates the 12 folders created on the disk repository of the development environment, according to an embodiment of the present invention.
FIG. 12 illustrates the dataflow for step 1 to step 3 for producing the certified authorized software components, according to an embodiment of the present invention.
FIG. 13 illustrates the dataflow for step 4 to step 12 for producing the certified authorized software components, according to an embodiment of the present invention.
FIG. 14 illustrates the grouping of gaming terminals and the associated enforced policies, according to an embodiment of the present invention.
FIG. 15 illustrates a method for enforcing a Software Installation Policy by “linking” the policy, according to an embodiment of the present invention.
FIG. 16 illustrates a method for enforcing a Software Restriction Policy by “linking” the policy, according to an embodiment of the present invention.
FIG. 17 illustrates the method to enforce a policy at a predetermined time, according to an embodiment of the present invention.
FIG. 18 illustrates the method to enforce a selected policy as the result of observing the gaming activity, according to an embodiment of the present invention.
FIG. 19 illustrates the method to generate dynamically the menu list of authorized game made available to the player on each gaming terminal, according to an embodiment of the present invention.
FIG. 20 illustrates the method to generate a code signed companion software component, according to an embodiment of the present invention.
FIG. 21 illustrates the method to quickly generate dynamically the list of game installed on each gaming terminal using the companion software component, according to an embodiment of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the construction and operation of preferred implementations of the present invention illustrated in the accompanying drawings. The following description of the preferred implementations of the present invention is only exemplary of the invention. The present invention is not limited to these implementations, but may be realized by other implementations.
FIG. 1 illustrates Software Component Identification and Traceability via File Properties, according to an embodiment of the present invention. Shown at 100 in FIG. 1 is the intrinsic information that uniquely identifies each executable software component. The executable component source code comprises executable code lines (e.g. X=X+1; not shown here) and associated source code assembly information 102 , 104 that comprises comment lines 106 and assembly information. Herein, AssemblyTitle 108 , AssemblyProduct 110 and AssemblyVersion 112 are configured. The AssemblyTitle 108 is set to CyberInv.exe that is the friendly name of the executable software component; AssemblyProduct 110 is set to 0006-00001-00 that is the part number of the executable software component and AssemblyVersion 112 is set to 1.0.1.0, which is the version number of the executable software component. Once the source code is compiled and the executable is built (Cyberlnv.exe in this case), the configured assembly information is available via the File Property of Windows 114 when right clicking on the file Cyberlnv.exe and selecting “Properties” and “Version”, as shown at 116 . The friendly name is shown in the Description field 118 , the part number is shown in the Product Name field 120 , 122 and the version is shown in the File Version field 124 .
It will be apparent to those of skill in the art of software development that intrinsic information that uniquely identifies each executable software component may be obtained in various combinations of assembly directives and file property fields. Additional information may be configured such as, for example, the software component part number, major version number, minor version number, build number, revision number, project name, type of software component, language variant, game regulation variant, friendly name, identification of the game certification laboratory, identification of the client, and other predetermined identification identifiers. The identifiers associated with the executable software component using source code assembly directives may, therefore, be traceable via the File Property features of the Windows operating system.
An example of such a configuration is CST3000-0006-00001-00[1.0.1.0]{21}^11˜9% S CyberInv.exe that comprises a concatenation of identifiers that may be used in a file name or a PKI certificate subject name. According to this example, CST3000 is the marketing system product identification or the project name; 0006-00001-00 is the software component part number; [1.0.1.0] details the software component major version number, minor version number, build number, revision number; {21} is the software component variant identifier; ^11 identifies the game certification laboratory that certifies the software component; ˜9 identifies the customer for which this software component is certified; %S is the software component language variant (“S” for Spanish in this example); CyberInv.exe is the software component friendly name for quick identification. Spaces may be used freely and the identifier fields may be written in any order so as to facilitate reading. Identifier fields may be omitted whenever the context already provides such information. The framing or delimiter characters such as [ ], { },˜, ^, % which are allowable characters to be used in file names and certificate subject names facilitate human recognition as well as string searches for particular attributes (global search for all Spanish variants for example).
In the same manner, a selected set of identification information making up the certificate subject name may be used for making up the file name of PKI certificate related files such as *.CER, *.P7B and *.PVK such as to facilitate human identification, string searches and file searches.
FIG. 2 illustrates traceability via the Windows Event Log. Reference numeral 200 in FIG. 2 illustrates the information uniquely identifying each executable software component being made available to the Windows Event Log upon execution of the software component. The Windows Event Log 202 is a repository for logging important events; it is viewed via the Event Viewer 204 . Windows default event log bins (or containers) are Application, Security and System. In the illustrated example, an Event Log bin 206 denominated “Cyberscan” has been added. The Cyberscan bin 206 contains traceability information in its “Source” field that is being logged by each of the executable software components. The software executable software component makes use of the Event Log API to “splash” its identification information into the source field of a predetermined bin in the Windows Event Log each time it starts execution, or at any other time should the occurrence of an event be traced, in order to provide an audit trail to be examined by auditors. The part number 214 , version 216 and friendly name 212 identifiers associated to the executable software component using source code assembly directives 201 are therefore traceable via the Event Log features of the Windows operating system. Other information associated with the executable software component may be splashed into the event log for additional traceability. The “Type” field 208 may flag an important audit condition such as here “Failure Audit” to alert the auditor.
FIG. 3 illustrates the Certificate “Issued to” Field. Reference numeral 300 illustrates the information 308 (test certificate indicator 318 , project/product code 320 , type of executable code 322 , part number 324 , major/minor/build/version 326 , game certification laboratory identifier 328 , friendly name 330 ) uniquely identifying each executable software component being used to generate the “Subject Name” 316 (or “Issued to” field 306 , 314 , or also known as the “CommonName” field) of the individual PKI certificate 304 associated with each executable software component, according to an embodiment of the present invention. The friendly name, part number and version of the executable software components may be substantially identical to those entered in the source code assembly 302 . “Subject Name” 316 and “Issued to” field 306 , 314 refer to the same information; Subject Name is preferably used hereafter. The certificate authority 312 responsible for generating the PKI certificate is shown in the “Issued by” field 310 .
FIG. 4 at 400 illustrates the information that may be entered in the Extended Attributes 408 of a PKI certificate 402 , according to an embodiment of the present invention. This information may be viewed by selecting, for example, the “Details” tab 404 of the certificate 402 and selecting “Extensions Only”, as shown at 406 . Intrinsic information that uniquely identifies each executable software component may be entered in the extended attributes of a PKI certificate in order to attain the same purpose as described for FIG. 3 as an alternative to entering the information in the certificate Subject Name. In the same manner, additional identification information to those entered in the Subject Name may be entered in the extended attributes.
FIG. 5 illustrates traceability via the Trusted Inventory Tool 504 , according to an embodiment of the present invention. Reference numeral 500 in FIG. 5 illustrates the information that may be obtained using the Trusted Inventory tool 504 . The trusted inventory tool 504 is a simple application that searches for executable files through the branches of a given tree directory and determines whether the executable software component may be trusted by, for example, calling the Microsoft ChkTrust.exe tool. If the executable software component is signed by a valid PKI certificate and its executable binary data is uncorrupted (its recalculated hash matches the code signature), the ChkTrust.exe tool returns the authenticode “Trusted” attribute; an “Untrusted” attribute is returned otherwise. The Trusted attributes are automatically tabulated in a spreadsheet such as, for example, Microsoft Excel as depicted at 506 . Each line 508 in the table provides details on the executable software component that is being examined, such as program path location 510 , friendly name 512 , executable type 514 , authenticode trusted attribute 516 , part number 518 and version 520 . According to an embodiment of the present invention, therefore, the part number 518 , version 520 and friendly name 512 514 identifiers associated with the executable software component using source code assembly directives 502 are traceable via the Trusted Inventory tool.
Reference numeral 600 in FIG. 6 illustrates the information that may be entered to configure a type-certificate Software Restriction Policy rule. A Software Restriction Policy (SRP) 604 may be configured using the Group Policy Object Editor 606 . The type-certificate Software Restriction Policy rule 610 may be entered in the “Additional Rules” node 608 of the Software Restriction Policy object 614 . In FIG. 6 , the part number, version and friendly name configured in the source code assembly 602 are recognizable in the certificate subject name 612 .
FIG. 7 illustrates SRP Certificate Rules Policies via the Group Policy Management Console, according to an embodiment of the present invention. Reference numeral 700 in FIG. 7 illustrates the policies that are associated to the active directory container used to configure the gaming machines referenced at 706 . Policies are managed using the Group Policy Management Console 702 , 704 . In this illustration, a policy named “SRP_CyberInv” 708 , 710 , 712 is selected, for the purpose of viewing a detailed report of the rules that are configured. The report shows details in a hierarchical order. This exemplary policy defines only one certificate rule 716 in the Software Restriction Policy node 714 . The certificate subject name 718 is set with a security level 720 of “Unrestricted”, as shown at 722 , thus ensuring that only the executable software component identified in the certificate subject name is authorized to execute when the policy 714 is enforced. The SRP path rules 724 must be configured such as to prevent non-authorized software from executing. The policy 708 is enforced when it is linked to its container object 706 herein named “Gaming Machines”.
Reference numeral 800 in FIG. 8 illustrates an exemplary cycle from the moment a game is being created until it is first executed on a gaming terminal, according to an embodiment of the present invention. The flowchart 800 starts at 802 when the decision to initiate a project to develop and release a new game is made. The game developer (Cyberscan here, for illustrative purposes only) 804 develops a new game application 806 whose code must be certified at 810 by a recognized game certification laboratory 808 . The certified code must then be signed as shown at 812 using PKI certificates produced by a certificate issuing authority (CA) 814 controlled by a trusted party 816 . The trusted party 816 may be the game certification laboratory 808 . The signed executable software components may be packaged in code-signed MSI installation packages signed in a manner substantially identical to the executable software components, that is, with a unique PKI certificate whose subject name contains part number, version and friendly name identifiers for the MSI package. The MSI packages together with scripts may then be copied to a removable media, such as a CD-ROM 818 for example.
The game operator 820 receives the CD-ROM and when it decides to deploy the new game 822 , it copies the packages and associated scripts from the removable media into a library repository on a server 824 (the DEPLOY server in this case). The scripts contain automation tasks such as copying to the repository and configuring the policies.
In the case of gaming terminals connected in a LAN, each gaming terminal 826 is controlled by the policies as soon as they are enforced. The Software Installation Policies (SIPs) controlling the installation of the new game automatically execute the MSI installation packages upon policy enforcement, provided the corresponding Software Restriction Policies have been configured to authorize the execution of the MSI installation packages. This process is performed at 828 , 830 . If no SRP authorizes the execution of the MSI installation packages, the installation is ignored, as shown at 832 . When the MSI installation package is authorized to execute, the software components and other files contained in the package may be copied to the gaming terminals, as suggested at reference numeral 834 836 .
Other configuration tasks may also be carried out during the Microsoft installer installation process such as, for example, setting the Windows registry, setting shortcuts and installing software patches. Patches (e.g., updates) to the game software and/or related files may be applied and sequenced according to, for example, the method outlined at http://msdn.microsoft.com/library/en-us/msi/setup/patching.asp. The Microsoft Windows Installer is integrated with Software Restriction Policy in Microsoft Windows XP, and may be used to administer software patches to the game software components submitted to the software development environment of the game certification laboratory. However, embodiments of the present inventions are not limited to the use of Microsoft Windows Installer. In Microsoft Windows Installer, the Software Restriction Policy is configurable through group policy, and allows an administrator to restrict installation of packages using a certificate rule. The software restriction policy may be evaluated the first time a package is installed, when a new patch is applied, when the installation package is re-cached and when uninstalling the installation package. Multiple patches may be applied to a product in a constant order, regardless of the order that the patches are provided, by providing patch sequencing information into the MsiPatchSequence table of the patch installation package. Installed patches may be uninstalled singly, and in any order, without having to uninstall and reinstall the entire application and other patches.
The Windows Installer provides many built-in actions for performing the installation process. Standard actions are sufficient to execute an installation in most cases. However, there are situations where the developer finds it necessary to write a custom action and to include these custom actions in the installation package to be submitted to the software development environment of the game certification laboratory. The installation package may be code signed with a PKI certificate issued by a trusted certificate authority, and these custom actions may be trusted when the package is code signed. For example, the custom actions may be operative to perform automation operations in the software development environment of the game certification laboratory during the installation and/or un-installation of the installation package. Custom Actions may be written to, for example, launch an executable during installation that is installed in the software development environment of the game certification laboratory, to call special functions during an installation that are defined in a dynamic-link library (DLL), to defer the execution of some actions until the time when the installation script is being executed, or run a nested installation on the software development environment of the game certification laboratory, for example. Additional information on such custom actions are available at http://msdn.microsoft.com/library/en-us/msi/setup/custom_actions.asp.
Download of the game software components from the game repository to the gaming terminals may occur as soon as the associated Software Installation Policies are enforced (and the SRPs for the MSI installation package is permitted accordingly). Therefore, scheduling of the download may be achieved by simply enforcing the associated software installation policies at a given time; this may be accomplished by having an operator manually enforcing the SIP at a predetermined time via the group policy management console, or having a process automatically enforcing the SIP at a predetermined time via the API to the group policy management console. Enforcing a policy may be achieved by linking the selected policy to the selected policy object in the domain controller active directory.
Game activation 840 that authorizes execution of the game may be achieved by enforcing the associated Software Restriction Policies. In the same manner, scheduled game activation and deactivation in order to offer selected authorized games to the players at predetermined authorized times may be achieved by simply enforcing the associated Software Restriction Policies at a given time; this may be accomplished by having an operator manually enforce the SRP at a predetermined time via the group policy management console, or having a process automatically enforce the SRP at a predetermined time via the API to the group policy management console. Enforcing a policy may be achieved by linking the selected policy to the selected policy object in the domain controller active directory. Alternatively, a selected executable software component may be prevented from executing by configuring its associated SRP security level to “disallowed”.
At this stage, a global verification process 842 , 844 as described relative to FIG. 9 may advantageously be executed to verify the trust of every software component installed on the gaming terminal. Should the global verification fail, the gaming terminal may be locked at 846 pending servicing by an attendant.
When a player selects a game from a gaming terminal 838 from a selection menu and requests execution thereof, as shown at 848 , the authenticodes of the game's executable software components are verified by the associated enforced Software Restriction Policy as shown at 850 before beginning execution 858 . Should the authenticode verification fail at 852 , the gaming terminal may be locked at 854 pending servicing by an attendant. If the code is trusted, as verified by the associated enforced SRP, the game is allowed to execute, as shown at 858 .
Policy changes are automatically distributed by the Windows server operating system throughout the network connected gaming system at periodic intervals; this automatic process may be disabled if required. Alternatively, the RegisterGPNotification function may be used by the game application software executing on each gaming terminal to check if an applicable group policy has changed. The gaming terminal may then decide on enforcing the policies locally immediately. The gpupdate.exe service, the RefreshPolicy function or the RefreshPolicyEx function may be used by the game application software executing on each gaming terminal to enforce the configured policies. A reboot may optionally be performed in order to recheck the gaming terminal trusted base and ensure the policies have been completely enforced (long game installation for example).
The RegisterGPNotification function enables an application to receive notification when there is a change in policy. When a policy change occurs, the specified event object is set to the signaled state. Further information on the RegisterGPNotification function may be found at: http://msdn.microsoft.com/library/default.asp?url=/library/en-us/policy/policy/registergpnotification.asp. The RefreshPolicy function causes policy to be applied immediately on the client computer. Further information on the RefreshPolicy function may be found at: http://msdn.microsoft.com/library/default.asp?url=/library/en-us/policy/policy/refresh policy.asp. The RefreshPolicyEx function causes policy to be applied immediately on the computer. The extended function allows specifying the type of policy refresh to apply to be specified. Further information on the RefreshPolicyEx may be found at http://msdn.microsoft.com/library/default.asp?url=/library/en-us/policy/policy/refreshpolicyex.asp.
The menu of authorized games offered to the player may be dynamically generated by each terminal without requiring the central system to dispatch the list of authorized games or having each terminal fetch the list of authorized games from the central system; this may be done by having each terminal check the policies enforced on the games. This may be accomplished by having a process in each terminal attempt to execute each of the entry point for each game (the parent module which is first called upon selecting a game to play) . If the execution succeeds, then the game is authorized and may be added to the games menu offered to the player. If the execution is denied (SRP is unlinked or the security level is disallowed), then the game is not authorized and it is removed from the games menu offered to the player. Similarly, if a game entry software component file is not found, then the software is not installed or has been removed and is removed from the games menu offered to the player. The process of dynamically generating the game selection menu may be optimized in many ways in order to reduce the game time to start overhead to check if it is authorized.
In a casino, although new games may be scheduled to be downloaded to gaming terminals and activated at predetermined times, it is a requirement that games may not be changed while a player is playing. In practical terms, a player is considered to have terminated his or her game play when the player's credit balance remains at zero for a predetermined period of time. The predetermined period time is sufficient for allowing the player to enter a new bill or other form of credit instrument to continue playing. Therefore, the game application software on each game terminal may, according to embodiments of the present invention, continually test for this condition (credit=0 for a predetermined time) before checking for change in policy, enforcing the policy changes and then updating the menu of games to be made available to the next player.
FIG. 9 at 900 illustrates the global verification process performed by a terminal to check that no unauthorized files are allowed to execute or affect the game outcome. This process may be performed by any of the subsystems connected in the gaming systems.
The process may start with a computer cold or hot reboot 902 such that the operating system trusted base may be thoroughly verified before the game software components are verified. The trusted base is detailed in commonly assigned and copending US application Ser. No. PCT/US2002/029927, entitled “Secure Game Download”, the specification of which is incorporated herein by reference, and also in Microsoft Next Generation Secure Computing Base (NGSCB), also incorporated herein by reference. Details of Microsoft's NGSCB are located at www.microsoft.com/ngscb. During the trusted base verification, the integrity of the Driver Signing framework, the Windows File Protection framework and Software Restriction Policies framework are verified. With NGSCB operating system such as forthcoming “Longhorn”, a framework called Nexus deeply integrated directly within the hardware components (in each major chipsets) and the BIOS which constitutes a mechanism for authenticating the trustworthiness of the software and hardware configuration, is booted prior to checking the integrity of the Driver Signing framework, the Windows File Protection framework and Software Restriction Policies framework.
On completion of the operating system boot-up 902 or at another time, the global verification process 904 may be executed. The CyberInv process 910 , 914 is also shown and described at FIG. 5 . The CyberInv process 910 , 914 verifies all the executable files in given folder trees such as 912 (*.exe, *.dll, *.ocx, *.vbs, *.bat, *.msi, *.cab, for example) for trustworthiness. If any file is found to be untrusted as shown at 932 , then the gaming terminal may be frozen as shown at 934 pending examination by security personnel. A spreadsheet file 916 may be produced that list the verification status of each executable file. If the authenticode of all the files is trusted as shown at 918 then the CyberInv process 908 , 910 , 914 , 924 returns at 920 a trusted status, as shown at 926 930 . Consequently, all of the executable software components may be considered to be trusted, as shown at 930 .
However, it is to be noted that the fact that an executable software component is trusted does not imply that the software component is authorized to execute; it merely indicates that the software executable software component has a valid authorized authenticode certificate and that the software component binary data is not corrupted. Checking whether an executable software component having a valid authorized authenticode certificate is authorized to execute requires that the applicable Software Restriction Policy be checked. This may be performed automatically when the software component is loaded by the operating system to start its execution, either when dynamically building the menu of authorized games, or each time upon starting execution of the game when the player has selected a game to play—or using an appropriate service that may be called by an application.
Although RM (Rights Management) and DRM (Digital Rights Management) technology from Microsoft is readily available for authenticating the trustworthiness of non-executable files such as media files, Word files and emails, for example, it adds management complexity on top of the Software Restriction Policy framework when used in a network-connected gaming system. Addressing this, embodiments of the present invention offer a method for a network connected gaming system to trust non-executable files such as initialization or configuration files, video files, sound files, multimedia files, file containing list of hashes, CRCS, and/or signatures. The present method relies on packaging the non-executable files in a MSI installation package, the MSI package being subsequently code-signed with a unique certificate and the appropriate Software Restriction Policy is configured to enable installation (execution in fact) of this MSI package. Executable files and non-executable files may be packaged together for convenience. The selected aggregate of executable files and non-executable receives at least a part number (and preferably a version number as well) that is used in the subject name of the associated certificate. Consequently, according to embodiments of the present invention, when the MSI package is installed, the installed non-executable files are obtained from a trusted and authorized source.
As the Cyberlnv process 908 has authenticated the trustworthiness of all the *.msi files 911 , therefore whenever there is a need to ensure that the non-executable files are trusted, the associated MSI package is re-installed. It is to be noted that the service that performs the installation of the MSI packages (msiexec.exe in the current versions of Windows) may be executed with a variety of execution modifiers, such as shown at http://www.microsoft.com/technet/treeview/default.asp?url=/technet/prodtechnol/winxppro/proddocs/msiexec.asp. Of particular interest is the c option that reinstalls a file if it is missing or if the stored checksum of the installed file does not match the new file's value (the log file will contain the anomalies detected for subsequent forensic analysis), as shown at 936 . In the global verification process 904 , the c option of the msiexec.exec command may be used for re-installing every package containing configuration files 938 (such as initialization or configuration files, files containing list of hashes, CRCs, and/or signatures), Flash files 940 (Macromedia Flash and Director), and other media assets files 942 in order to ensure the trustworthiness of these files.
Subsequent to completion of process 908 , all the MSI packages for the executable software components may be re-installed with for example, the msiexec.exe command using the p option in order to re-install missing authorized executable software components (the log file will contain the anomalies detected for subsequent forensic analysis).
Subsequent to the successful completion of the global verification process 904 , the trustworthiness of the game application framework is established and may be started, as shown at 906 .
It is to be noted that when a player wins an amount equal to or greater than $25,000 in a casino, there is a requirement to check the integrity of the gaming application. With legacy gaming terminals, the gaming terminal is powered-down and the ROMs are extracted in order to be verified in a trusted verifier named a “Kobetron”. The Kobetron produces a signature for each of the ROMs that is compared with the corresponding signature produced by the game certification laboratory. In this manner, the integrity of the all the software components of the legacy gaming terminal, including the operating system, the game application and the configuration data may be verified. According to embodiments of the invention, when executing the global verification process 904 subsequent to the gaming terminal bootup at 902 , a verification equivalent to a “Kobetron verification” may be performed. This metaphor helps greatly in the acceptability of downloadable game technology by game regulators who are reluctant to accept state-of-the-art operating systems, multimedia and network technologies.
FIG. 10 at 1000 illustrates the configuration of the three parties involved in a new game cycle detailed at FIG. 8 , according to an embodiment of the present invention. The three parties involved in a game cycle, according to embodiments of the present invention, are the game developer 1002 whose facilities are located in a given city 1004 , the game certification laboratory 1006 whose facilities are located in a given city 1008 and the gaming operator 1010 located in a given city 1012 . The game developer 1002 and the game certification laboratory 1006 may have a network 1020 of connected gaming system(s) representative of the network connected gaming system in place at the location (e.g., the casino) of the gaming operator 1010 . In addition, the game developer 1010 and the game certification laboratory 1006 each may have an integrated software development environment for compiling the game applications source code, each capable of managing at least 200 games for 50 distinct game operators as shown at 1044 , (resulting in thousands of source code variants due to local regulation variances). The development environments may be kept synchronized via the secure network link 1016 , 1018 , 1014 , 1022 , 1020 . A certification authority (CA) 1040 may be located at the game developer's site or may be controlled by an authorized trusted party such as VeriSign. The game developer site and the game certification laboratory site may be accessible from the outside by authorized mobile users 1034 , 1028 via secure links 1022 , 1018 , 1030 , 1036 . Logon authentication may be carried out using, for example, smartcards as shown at 1038 , 1032 or by other secure means.
According to one embodiment of the present invention, the game developer 1002 may supply the game certification laboratory 1006 with a CD-ROM (or other media) containing the software components to be tested, as shown at 1048 . The game certification laboratory then certifies the software components supplied on the CD-ROM and provides the game developer 1002 with a CD-ROM containing the certified software components for deployment, as shown at 1046 . The CD-ROM 1046 containing the authorized software components that were tested and certified by the game certification laboratory 1006 may then be provided to the game operator (e.g., the casino) for installation and deployment on one or more of the gaming machines GM 001 , GM 002 , GM 2995 coupled to the network 1024 . The certified authorized software components are code-signed using a certificate produced in accordance with an embodiment of the present invention, as described hereinabove. The network 1024 is preferably not coupled to any external network, as suggested at 1026 .
FIG. 11 shows a 12-Step Integrated Certification Environment Process, according to an embodiment of the present invention. Shown at 1100 are the 12 folders 1110 created on the disk repository 1102 of the development environment. The 12 folders 1110 are mapped to the 12-step procedure 1104 to 1106 involved in producing the CD-ROM 1050 containing the certified authorized software components. Each folder contains the computer resources and instructions to carry out each step. The folders are clearly named with the step number and the title description of the procedure step at 1108 .
FIG. 12 shows a dataflow diagram of Step # 1 to Step # 3 of the Integrated Certification Environment Processor for producing certified authorized software components, according to an embodiment of the present invention. Step 1 at 1220 may include obtaining a snapshot 1212 of the repository 1204 containing the game developer's source code 1206 , data files 1208 and media assets 1210 in order to configure the building environment of the reference platform with all the source code, data files, media asset files and resources files required to initiate the certification process. The snapshoot files 1212 may be stored in a repository 1218 controlled by a version configuration and control system (SCCS) such as Microsoft Visual Source Safe 1214 (VSS) on the DEV development computer 1216 . The files may be grouped in project directories as “Projects” such that the source files, control files and resource files are stored in convenient systematic fashion in the Visual Studio repository 1240 on the development computer 1238 . An inventory of the files submitted for certification may be produced. Step 1 may be qualified as “SETUP Projects” 1222 .
Alternatively and according to an embodiment of the present invention, the gaming developer may provide the game certification laboratory with only the source code that is to be certified. As set out above, such source code may be provided to the game certification laboratory on a CD or other tangible medium containing the software to be certified stored thereon. Alternatively and according to another embodiment of the present invention, the source code to be certified, along with any related files may be packaged in an installation package, shown at 1219 in FIG. 12 , that binds together all of the source code to be certified and ancillary files including data files, installation scripts or directives, VB sources, configuration files and video assets, for example. The installation package 1219 may receive a distinct certificate bound to its content by a code signing operation. The attributes of such installation package 1219 may be defined so as to indicate the installation package's destination (e.g., Visual Studio environment at the certification lab). Therefore, instead of sending both source code and the corresponding executables (including binary files and other files created through the compilation process) to the game certification laboratory as shown at Step 1 1220 in FIG. 12 , only the source code (together with the ancillary files) may be sent to the certification lab. Moreover, such source code and ancillary files may be packaged within an installation package 1219 secured by a (e.g., PKI) certificate. Indeed, the installation package 1219 may be a code-signed installation package signed a unique PKI certificate from a trusted issuing authority. The installation package 1219 may be executed, within the certification lab's environment, using an action script or directive that was packaged within the installation package. The action script may be configured to control the installation process (or alternatively, carry out updates or uninstall operations) of the packaged source code in an orderly and controlled fashion. After the installation package 1219 has been installed within the gaming certification lab's development environment, the remaining steps 2 - 12 of FIGS. 12 and 13 of the certification process may be carried out, as described elsewhere herein. After the certification process is finished, the installation package 1219 may be removed from the certification lab's source code management environment, again according to one or more action scripts packaged within the installation package 1219 originally sent to the certification lab. The removal process preferably removes all source code, executable and ancillary files related to the submission from the certification lab's code management environment. To carry out the removal in an orderly and controllable fashion, action scripts included in the original installation package 1219 submission (or provided later) may be executed to remove and/or delete all files related to the compilation process carried out during the course of the certification process. Both the installation and eventual removal of the installation package 1219 may be carried out by the certification lab. Step 1 at 1220 in FIG. 12 may also include a step of executing the installation package, to provide the game certification laboratory with the source code to be certified.
According to an embodiment of the present invention, the installation package 1219 may include an installation package from Microsoft Corporation, such as an .MSI package. Preferably, the installation package is not limited to the Windows® operating system, but is also compatible with other operating systems, such as UNIX and LINUX. The installable submission package provided to the game certification laboratory may include a file name identifier that may reflect the certification process thread and stage, that is, may denote the customer, the applicable regulation, initial submission, bug fix, regulatory variant, retirement, etc. The file name identifier may advantageously be or include a text string comprising the relevant explicit codes and/or a GUI (Global Unique Identifier) associated to the applicable certification process details. An installer utility may allow the game certification laboratory to unpack the package provided by the game developer and to execute any included directives or scripts (such as, for example, installation, updating or uninstalling of source code and any associated files). In the case of an update, the old source code (and related files) may be advantageously cached in a structured manner such that a given update may be undone, if requested.
It is to be noted that Steps 2 to 12 may be automated using, for example, the automation API of Microsoft Visual Studio 2003 (or MS-Visual Studio 2005, also known under its code name Whidbey. Step 2 at 1232 may include compiling the source code and producing binary executable code. Microsoft Visual Studio 1224 is constructed so as to manage source code as projects (a project can be a given game) regrouping all of the dependent source code, and data files. Step 2 is also referenced as building the projects or “BUILD Projects”, as shown at 1234 . Media assets may require a different compiling environment on the DEV computer 1230 such as the Macromedia Director 1228 .
Step 3 , shown at 1242 may include producing the project's MSI packages 1244 for the source code compiled in Step 2 . Relevant non-executable file such as configuration files and media assets may be packaged in MSI packages with the compiled source code. It is to be noted 1246 that packages will be built again (step 8 hereafter) after code signing of EXE, DLL, OCX and other executables (step 6 hereafter). Step 3 may be referenced as “BUILD Packages Pass # 1 ” 1244 .
FIG. 13 shows, at 1300 , the dataflow for step 4 to step 12 for producing the certified authorized software components, according to an embodiment of the present invention. Step 4 at 1308 calls for the CyberInv.exe process 1306 , for a selected project (a Visual Studio project may typically regroup all the software components for an entire game), perform an inventory 1304 of the compiled software components produced by Visual Studio 1302 on completion of the Build Project process 1234 ( FIG. 12 ) as well as the MSI install packages produced by the Build MSI Packages Pass # 1 1244 process ( FIG. 12 ). The CyberInv.exe 1306 process may also include any other executable software components not directly managed under Visual Studio such as, for example, ocx, *.vbs, *.bat, *.cab, *js. (in fact, any executable component that is supported by the Software Restriction Policy technology).
The CyberInv.exe process 1306 produces the CyberInv.xls 1307 Excel spreadsheet file 916 shown at FIG. 9 , which is examined by an authorized user in the MS Excel program 1310 . The CyberInv.xls 1307 file is copied to the folder “Step 4 —CyberInv” folder in 1110 in FIG. 11 . The binary files having just been compiled are not code-signed; consequently the authenticode field shows an “Untrusted” status for each of the binary components. The friendly name, file type, part number and version (including build number) are extracted directly from the assembly information contained in the source code, therefore truly reflecting the identity of the source code component.
Because the build number is incremented each time the code is recompiled in a Build operation, it is to be noted that the version number will change accordingly. The authorized user eliminates the rows that are irrelevant to the game to be certified and saves the file under the CyberCert.xls 1311 file name which contains the necessary friendly name 512 , executable type 514 , part number 518 and version 520 information to compose the PKI certificate subject name in accordance with method detailed at FIG. 3 for subsequent code signing. The program path location 510 of the unsigned software components is also available for later retrieval of the unsigned binary file. The CyberCert.xls 1311 file is copied to the folder “Step 5 —CyberCert” folder in 1110 in FIG. 11 .
The CyberCert.xls 1311 file may be securely copied in encrypted form to a removable media such as a floppy disk, a CD-ROM or a USB disk 1312 , or alternatively transferred to another location by secure communication means.
The CyberCert.xls 1311 file is split into 2 files CyberSign1.xls 1317 and CyberSign2.xls 1319 . CyberSign2.xls contains only the rows associated to the MSI packages and CyberSign1.xls contains the rows corresponding to the other executable file. CyberSign1.xls is copied to the “Step 6 —CyberSign (Pass # 1 )” folder in 110 in FIG. 11 , and CyberSign2.xls is copied to the “Step 8 —CyberSign (Pass # 2 )” folder.
Step 5 at 1316 includes having a certification authority (CA) 1315 located at the game developers' site or controlled by an authorized trusted party such as VeriSign generating certificates in accordance with the details provided in the CyberCert.xls 1311 file, that is, with a subject name created in accordance with the method detailed relative to FIG. 3 . An automated process CyberCert.exe 1318 executing on the off-line CA computer Windows server named CS 11 1314 may automate the generation of the PKI public certificates 1326 and the associated private keys 1328 using the CyberCert.xls 1311 file.
The trusted root certificate for the authorized CA 1320 is supplied to the certification lab, the game regulators or other parties for reference and for importing as a trusted root into the ICE computer system and the gaming system certificates store.
The public certificates 1326 and their associated private keys 1328 are forwarded to the DEV computer 1332 of the ICE system in encrypted form on a removable media such as a floppy disk, a CD-ROM or a USB disk 1324 , or alternatively transferred by secure communication means. Public certificates 1326 and their associated private keys 1328 that are associated with the MSI packages are copied into the “Step 6 —CyberSign (Pass # 1 )” folder in 1110 , and the other public certificates 1326 and their associated private keys 1328 that are associated with other software components are copied to the “Step 8 —CyberSign (Pass # 2 )” folder.
Step 6 1336 includes steps of code signing the non-MSI executable components listed in the CyberSign1.xls 1317 file using the corresponding public certificates 1326 and their private keys 1328 . The code signing may be performed using the SignCode.exe utility provided by Microsoft, or equivalent. A password may be required for the private key depending on the security option selected when generating the certificate at the CA. The CyberSign.exe process 1330 may automate the code-signing of all the non-MSI executable components listed in the CyberSign1.xls 1317 file using the friendly name, file type, part number and version (including build number) given in each row. The CyberSign.exe process may call the SignCode.exe utility or the equivalent API. During the code signing process, the compiled executable software components may be replaced at 1339 by their code-signed form. Step 6 is designated as “CodeSign Pass# 1 ” 1338 .
Step 7 at 1344 includes re-building all the MSI install packages 1345 performed during step 3 at 1242 . This time, the MSI packages contain the non-MSI code-signed executable components.
Step 8 at 1340 includes code signing the MSI executable components listed in the CyberSign2.xls 1319 file using the corresponding public certificates 1326 and their private keys 1328 . The code signing may be performed using the SignCode.exe utility provided by Microsoft, or equivalent. A password may be required for the private key depending on the security option selected when generating the certificate at the CA. The CyberSign.exe process 1330 may automate the code-signing of all the MSI executable components listed in the CyberSign2.xls 1319 file using the friendly name, file type, part number and version (including build number) given in each row. The CyberSign.exe process may call the SignCode.exe utility or the equivalent API. During the code signing process, the executable MSI software components may be replaced 1341 by their code-signed form. Step 8 is designated as “CodeSign Pass# 2 ” at 1342 . The executable MSI software components are copied as shown at 1371 to the CD Pre-Burn repository 1372 .
Because of the necessity of performing step 7 , the CyberSign 1330 code-signing process to be used for the ICE (Integrated Certification Environment) is designated a “2-Pass code-sign”, as indicated at 1334 .
Step 9 1366 includes (a) configuring the software restriction policy (SRP) 1360 for the ICE system test gaming terminals (via the active directory 1350 in the domain controller DC) with the certificate rules corresponding to the certificate produced at step 5 (the *.p7b certificate at reference numeral 1326 may be converted to *.cert certificates for compatibility reasons when configuring the SRP); (b) configuring the Software Installation Policy (SIP) 1368 for the ICE system test gaming terminals with the MSI packages produced at step 7 , then (c) using the GPMC (Group Policy Management Console) or equivalent service, exporting the SIP via SIP export scripts 1362 and the SRP via SRP export scripts 1364 (the policy export facility is available in the Group Policy Management Console GPMC 702 , 704 ). These SIP and SRP export scripts may be copied into the folder “Step 9 —SIP & SRP” folder in 1110 . These SIP and SRP export scripts may be later imported in the gaming operator's 1010 gaming system for enforcing the policies on the game components. SIP export scripts 1362 and SRP export scripts 1364 are stored in the CD Pre-Burn repository 1372 (or into the folder “Step 10 —CD Burn—Casino Release” folder in 110 ).
Step 10 at 1374 includes steps of burning at 1384 to a CD-ROM 1376 or other removable media the content of the CD Pre-burn repository 1372 comprising (a) the executable MSI software components 1371 ; (b) the SIP export scripts 5 1362 and SRP export scripts 1364 and (c) other automation scripts in order to automate the installation of (a) and (b). A copy of CD-ROM 1376 may be forwarded (a) to the gaming operator's 1010 gaming system for game deployment (such as a casino 1379 ), (b) to the game certification laboratory 1378 , and (c) a trusted party 1377 such as a lawyer or in escrow for impartial reference in case of later dispute. The CD-ROM 1376 may later be inserted at 1050 in the gaming operator's 1010 gaming system for game deployment.
Step 11 at 1370 includes steps of (a) taking a snap-shot 1387 of the entire development environment for a selected certified game (Visual Studio repository 1302 and Visual Source Safe repository 1214 1218 that contains all the source file, the compiled code-signed executable files and dependant executable files, the non-executable. files, project solution, automation scripts, the source and compiled signed code from other development platforms, the media assets from media development platforms such as MacroMedia Director 1228 ); in (b) taking a snap-shot 1387 of the code-signed MSI installation packages; in (c) optionally encrypting them; and then in (d) copying them into a CD pre-burn repository 1388 (or into the folder “Step 12 —Burn—VS Snapshot” folder in 1110 ).
Step 12 at 1386 includes steps of burning at 1382 to a CD-ROM 1380 or other removable media the content of the CD Pre-burn repository 1388 comprising the software components of step 11 . A copy of CD-ROM 1380 may be forwarded to the game certification laboratory 1378 and to a trusted party 1377 such as a lawyer or in escrow for impartial reference in case of later dispute.
Steps 4 to step 12 should be carried out each time a source code is being recompiled subsequent to a modification because a unique certificate must be associated to each build. Deviating form this order may jeopardize certificate integrity because of the risk of a human error that may result in the wrong certificate being used during the code signing process.
FIG. 14 illustrates assignment of policies by banks of gaming machines. Reference numeral 1400 in FIG. 14 shows the grouping of gaming terminal and the associated enforced policies. In this illustration, the Group Policy Management console 1402 may be configured such that the active directory Organization Unit (OU) named “Gaming Terminals—Floor” at 1404 is architectured to regroup the gaming terminals in “banks” or sub-Organization Units (sub-OUs) identified by 200 A 0 x 1406 , 200 B 0 x 1408 , 200 C 0 x 1410 , and 200 D 0 x to 200 K 0 x at reference numeral 1412 . Each bank contains a predetermined number of gaming terminals, in multiples of 8 units, for example.
Noting the hierarchical tree composed of the OUs and sub-OUs illustrated at 1400 , all the policies 1414 apply to the OU “Gaming Terminals—Floor” 1414 which contains all the sub-OUs 1406 1408 1410 and 1412 . Using this technique, all the policies 1414 may apply to all the 3000 gaming terminals of a large casino. In the same manner, the policies 1416 , 1418 apply to the bank 1406 ; the policies 1420 , 1422 apply to the bank 1408 ; and the policies 1424 , 1426 apply to the bank 1410 .
In the illustration, the exemplary game named “Roulette” is assigned a policy named “Sbm1.5—SIP—Roulette (GLI)” 1416 which configures the Software Installation Policy (SIP) and a policy named “Sbm1.5—SRP—Roulette (GLI)” 1418 which configures the Software Restriction Policy (SRP) for that game.
In the same manner, the exemplary game named “Infinity” is assigned a policy named “Sbm1.4—SRP—Infinity (GLI)” 1424 which configures the Software Installation Policy (SIP) and a policy named “Sbm1.4—SRP—Infinity (GLI)” 1426 which configures the Software Restriction Policy (SRP) for that game.
The keyword “Sbm1.4”, in this example, denotes the certification submission number 1 . 4 , and the keyword “GLI” denotes the game certification laboratory GLI (Game Laboratories International) approving the Infinity game software.
In the illustration, all of the game terminals regrouped in the bank 200 A 0 x shown at 1406 are, therefore, configured to execute the Roulette game, all the game terminals in the bank 200 B 0 x shown at 1408 are configured to execute the Roulette game and the Infinity game, and all the game terminals in the bank 200 C 0 x shown at 1410 are configured to execute the Infinity game.
FIG. 15 shows the enforcement of a Software Installation Policy (SIP). In FIG. 14 , banks of gaming terminals are configured to execute authorized games using SIPs and SRPs policies. However, in order for the gaming terminals to be able to install a game, the associated Software Installation Policy must be enforced. At 1500 , FIG. 15 illustrates a method for enforcing a Software Installation Policy by “linking” the policy, according to an embodiment of the present invention. This is accomplished in the Group Policy Management console 1502 by, e.g., right-clicking the selected policy 1504 , 1506 “Sbm3.3—SIP—INFINITY — 95” associated to the Infinity game with a Return To Players (RTP) percentage of 95% and selecting the “link Enabled” attribute 1514 . The software components for the Infinity — 95 game contained in the two MSI installation packages 1510 and 1512 will subsequently be installed, provided the associated SRPs are configured to authorize execution of these two MSI packages (refer to description for FIG. 16 ). Alternatively, the same procedure may be automated via an API called from an appropriate application. It is to be noted that the linking of the policy will in fact enable the enforcement of the policy, but the policy will only be enforced on the gaming terminal when a gpupdate command or equivalent command is performed at the terminal; a terminal reboot may also be required for the policy to be enforced. Also to be noted is that policy changes are automatically distributed by the Windows server operating system throughout the network connected gaming system at periodic intervals; this automatic process may preferably be disabled such as to obtain more predictable policy enforcement changes by issuing explicit commands instead.
Package 1512 (friendly name: Infinity95.msi) contains the executable software components for the Infinity game and package 1510 (friendly name: Infinity95.ConFIG.msi) contains the configuration files (the non-executable files) for the Infinity game. Package Infinity95.ConFIG.msi 1510 is re-installed in the process 938 .
FIG. 16 illustrates the enforcement of a Software Restriction Policy (SRP). In FIG. 14 , banks of gaming terminals are configured to execute authorized games using SIPs and SRPs policies. However, in order for the gaming terminals to be able to execute the games, the policies must be enforced. FIG. 16 at 1600 illustrates a method for enforcing a Software Restriction Policy 1608 by “linking” the policy. This is accomplished in the Group Policy Management console 1602 by, e.g., right-clicking the selected policy 1604 , 1606 “Sbm3.3—SRP—INFINITY — 95” associated to the Infinity game with a Return To Players percentage (RTP) of 95% and selecting the “link Enabled” attribute 1624 .
The certificate rules 1610 , 1616 and 1620 that are configured with the “Unrestricted” attribute 1618 , 1622 authorize the installation of the software components for the Infinity — 95 game contained in the two MSI installation packages 1510 and 1512 by authorizing the unique PKI certificate associated to those MSI produced in accordance with the present method. The “.dll” executable software component 1612 is authorized, has its security level attribute set to “Unrestricted” and is, therefore, authorized to execute once it is installed.
The two MSI installation packages 1510 and 1512 for installing the software components for the Infinity — 95 game have their associated unique PKI certificate 1616 and 1620 (produced in accordance with the method described herein) configured with the “Unrestricted” security level attribute 1618 , 1622 via the certificate rules 1610 , thus enabling (or authorizing) execution and installation of the software components for the Infinity — 95 game.
The “.dll” executable software component contained in the 1512 package has its security level attribute set to “Unrestricted” thus it is authorized to execute once it is installed.
Alternatively, the same procedure may be automated via an API called from an appropriate application. It is to be noted that the linking of the policy will in fact enable the enforcement of the policy, but the policy will only be enforced on the gaming terminal when a gpupdate command or equivalent command is performed at the terminal; a terminal reboot may also be required for the policy to be enforced. Also to be noted is that policy changes are automatically distributed by the Windows server operating system throughout the network connected gaming system at periodic intervals; this automatic process may preferably be disabled such as to obtain more predictable policy enforcement changes by issuing explicit commands instead.
FIG. 17 illustrates a method at 1700 to enforce a policy at a predetermined time, according to an embodiment of the present invention.
Enabling enforcement of policies as described relative to FIG. 15 and FIG. 16 may be carried out interactively by an authorized user at predetermined authorized times, or alternatively may be controlled by a process at predetermined authorized times via the appropriate API. At the central system 1702 (the game download server in this illustration) at a given time 1704 , a user or a process may verify a change 1706 in the list of games to be made available to players on a selected set of gaming terminal banks. In case of a schedule change as shown at 1710 (or other reasons such as introducing a new game or revoking an existing game), policies on the domain controller 1714 are being changed accordingly either interactively by a user in the Group Policy Management console as described for FIG. 15 and FIG. 16 , or by a process via the equivalent APIs 1712 . The changed policies are being enabled for enforcement at 1716 in the domain controller.
In a casino, although new games may be scheduled to be downloaded to gaming terminals and activated at predetermined times, it is a requirement that games are not to be changed while a player is playing. In practical terms, it is considered that a player terminates playing when his or her credit balance remains at zero for a predetermined period of time. The predetermined period time should be sufficient to allow the player to enter a new bill or other form of credit or payment instrument to continue playing. Therefore, the game application software on each game terminal continually tests for this condition (credit=0 for a predetermined period of time) before checking for change in policy, enforcing the policy changes and then updating the menu of games to be made available to the next player.
Upon power-up, each gaming terminal 1718 executes a boot 1720 , loads its operating system 1722 and enforces the policies 1724 that are configured at the time of the start-up process. When the game application starts at 1726 , it displays a menu of authorized activated games as shown at 1727 to the player using for example the dynamic method described relative to FIG. 19 . Whenever the player balance is non-zero 1728 , 1730 , the player may play as shown at 1732 the games listed on the menu in accordance with the enforced policies. When the player's balance reaches zero at 1734 and remains zero for a predetermined period of time, it is considered that the player is no longer playing. The gaming application of the gaming terminal may then verify at 1736 if a policy has changed 1738 . This may be done via the RegisterGPNotification. The RegisterGPNotification function enables an application to receive notification when there is a change in policy. When a policy change occurs, the specified event object is set to the signaled state. Additional details. regarding the RegisterGPNotification function may be found at http://msdn.microsoft.com/library/default.asp?url=/library/en-us/policy/policy/registergpnotification.asp.
At 1740 , if there is no change in policy, the games listed on the menu will be unchanged for the next player. If there is a change in policy at 1742 , the gaming terminal may enter into a process whereby the policies are enforced as shown at 1744 , using for example the gpupdate.com service, the RefreshPolicy function or the RefreshPolicyEx function, or equivalent services or API. It is to be noted that the verification of change in policy and the enforcement of the changed policies may be carried out by each terminal independently.
The RefreshPolicy function causes policy to be applied immediately on the client computer. Additional details regarding the RefreshPolicy function may be found at http://msdn.microsoft.com/library/default.asp?url=/library/en-us/policy/policy/refreshpolicy.asp
The RefreshPolicyEx function causes policy to be applied immediately on the computer. The extended function allows specifying the type of policy refresh to apply. Additional details regarding the RefreshPolicyEx function may be found at htt://msdn.microsoft.com/library/default.asp?url=/library/en-us/policy/policy/refreshpolicyex.asp
Once the change in policy is enforced at 1744 , the gaming terminal may reboot as shown at 1748 or exit and re-enter the gaming application, which would dynamically recreate the menu list of games 1727 to be made available to the next player, as detailed at FIG. 19 .
A similar method relying on explicit WMI calls and administrative templates (*.adm) may be applied to obtain the same result in gaming environments whereby the domain controller active directory is not available such is the case with gaming terminals connected in WAN (Wide Area Network) whereby the network bandwidth is limited or the network availability is poor.
An alternative method relying on SMS (System Management Server) code download instead of SIPs (Software Installation Policy) for installing software components and software MSI packages may be used. However, the executable software components remains under SRP (Software Restriction Policy) in accordance with the unique PKI certificate generated for each component as described in the invention.
FIG. 18 shows a close-loop enforcement of a policy, according to an embodiment of the present invention. FIG. 18 at 1800 illustrates a method to enforce a selected policy as the result of observing the gaming activity. The method is directly derived from FIG. 17 whereby the policy change 1716 takes place at 1804 and is selected from a choice of pre-configured policies, for example in a look-up manner, whereby a policy would result in making available to the players a menu of games 1812 ( 1727 in FIG. 17 ) to provoke a given gaming activity change which may be monitored in real-time at 1816 . The observed activity 1818 may then be compared 1820 to predetermined businesses objectives 1822 and a correction or modification may be applied by selecting a new policy that would change the list of games available on a selected aggregate of gaming terminals 1810 . For example, due to a long queue of people who want to play the Infinity game, a greater number of banks of gaming terminals may be configured to make the Infinity game available to players on these terminals. Another reason for applying a new policy might be if a particular area of the casino floor is heavily populated with players while another area is empty. Suppressing some popular games in a highly frequented area and adding them to the less frequently area may help spread the player distribution within the casino or gaming area more evenly. Yet another reason for applying a new policy could be if the gaming activity is low, then games with a higher RTP (return to player), let us say 98% instead of 95%, may be activated in some areas to boost activity.
The process may involve several subsystems as illustrated in FIG. 18 : the central game control 1802 wherein policies are selected, the domain controller 1806 that enables enforcement of the policies 1808 , a selection set of gaming terminals 1810 wherein each gaming terminal enforces the policies and make the selected games available to the player 1812 , a central game monitoring system 1814 that produces activity reports in real time 1816 .
The process shown at 1820 of comparing the observed activity 1818 and the targeted activity 1822 and then selecting a change in game policies 1804 may be carried out by the floor manager or the floor director, or alternatively by a knowledge base process. In both cases, a close-loop enforcement of policies (relying on the unique PKI certificate SRP associated to each executable authorized and certified software component) is achieved resulting in the dynamic configuration of the gaming system, either for LAN configurations (such as casino floors) or WAN configuration (such as video lottery terminals distributed across a large geographic area).
FIG. 19 at 1900 illustrates a method to generate dynamically the menu list of authorized games made available to the player on each gaming terminal, according to an embodiment of the present invention. The dynamic configuration of a large gaming system whereby authorized games made available to players on selected group of gaming terminals using software restrictions policies at the central system may result is hundreds of different game menus. Reliance on SRPs for preventing non-authorized software components to execute is entirely based on a sound and demonstrable trusted base; therefore the gaming system is trusted. Getting the list of authorized games to each gaming terminal would require configurations files to be sent from the central system to each of the gaming terminal; however, this would be illegal because the change in the list of games may affect the game outcome. This is clearly understandable when considering changing a game; let us say Infinity 95 with a RTP or 95% with Infinity — 98 with a RTP of 98% at 10:00 PM, then back at 8:00 AM, and this each day except during the weekend, or at other times as a result of the closed loop process described at FIG. 18 . Game regulators mandate that the process to manage this type of change be certified with secure means of the same order as when installing/downloading software components using a unique PKI method.
Embodiments of the present invention, therefore, provide secure means to update a list of authorized games to be offered to the player. The menu of authorized games offered to the player may be dynamically generated by each terminal without requiring the central system to dispatch the list of authorized games or having each terminal fetch the list of authorized games from the central system (both are illegal without extreme precaution of the same order as the installing/downloading of software components using a unique PKI method because they may affect the game outcome); this is achieved by having each terminal checking the certificate Software Restriction Policies enforced on the games (a unique PKI certificate being generated for each of the executable game components in accordance with the methods detailed in this document).
As illustrated in FIG. 19 at 1900 , each terminal when executing the gaming application 1902 gets a list of the file names for the games available at 1904 from a trusted configuration file (an updated trusted configuration file may have been downloaded in a certified code signed MSI package with the last game download) and a menu is initially compiled for this list. Attempts to execute each of the game entry module of the games contained in the list 1906 are made. If the game entry module is not found at 1910 , the software components do not exist on the gaming terminal and the game is removed from the menu 1912 , whereupon the process iterates to next game, as suggested at 1926 1928 . If the execution of the game entry module is denied at 1916 , 1918 because the Software Restriction Policy is preventing this game to execute, the game is removed from the menu as shown at 1920 and the process iterates to next game, as shown at 1926 1928 . If the execution of the game entry module is successful at 1922 , then the game is authorized and may be added to the games menu offered to the player. The process iterates through other games in the list, as shown at 1928 , 1930 , 1942 , 1906 , if any. Once the iteration is completed at 1932 , the games menu may be composed at 1934 and the menu is displayed to the player at 1936 .
FIG. 20 shows a companion Hello component, according to another aspect of the present invention. Reference numeral 2000 in FIG. 20 illustrates a method to generate a code signed companion software component. Each game comprises an aggregate of executable and non-executable software components, usually comprising files such as *.exe, *.dll, *.dat, *.xml. In general, all the software components are dependent of one component named the main program or the game entry. Starting the execution of the main game component is a lengthy process, as a large number of dependent executable components and graphics need to be verified (SRP verification) and started. Currently, there is no API available in the Windows operating system client computer for verifying the status of a Software Restriction Policy enforcement on a given software component applicable to that client computer.
Another embodiment of the present invention, therefore, provides a method to quickly verify the policy enforcement on a game without starting the entire game, in order to generate the list of available games to be made available to the player in a menu. For each game, a very short companion .dll file may be created having, for example, only one line of code<<Return “HELLO” >> which would return the exemplary “HELLO” string when called. Assuming “Infinity.dll” 2010 is the main game component file name 2002 (or friendly name), then the companion file may be named “Infinity.Hello.dll” 2018 . Preferably, the companion's 2018 source code would have in its assembly information a part number 2004 as shown at 2020 and a version number 2006 as shown at 2022 that is identical to the main component 2010 part number 2012 and a version number 2014 , but this is not mandatory. In addition, assuming the PKI certificate's subject name 2008 associated to the Infinity.dll is “GDS.exe.0099-0001-00[1.0.101.0] Infinity.dll” 2016 , which is used for the code signing of the Infinity.dll, we may proceed with the code signing of Infinity.Hello.dll with the same 2026 , 2028 “GDS.exe.0099-0001-00[1.0.101.0] Infinity.dll” certificate, as shown at 2024 .
It is to be noted that code signing two distinct software executables with the same certificate is a deviation from the method taught earlier in this document. However, the fact that the role of the companion file is very well defined, as having for example only one line of code<<Return “HELLO”>> which would return the “HELLO” string when called, this does not present an issue with the regulators or the certification lab.
FIG. 21 shows steps that may be carried out to search for games on each gaming terminal, according to yet another embodiment of the present invention. Reference numeral 2100 in FIG. 21 illustrates a method to quickly generate dynamically the list of games installed on each gaming terminal using the companion software component described above. The process of dynamically generating the game selection menu may be optimized in many ways in order to reduce the overhead of starting the execution of a game to check if it is authorized. However, if the aim is to sense for the enforced SRP or SIP applied to the game or detect local availability of the game software components, then such optimizations (among other possible variations) should be considered to be within the scope of the invention as defined by the claims hereunder. According to an embodiment of the present invention, a method is presented herewith to quickly generate the list of available games to be made available to the player in a menu without transfer of a file from the server. Reference 2100 is identical to reference 1900 in FIG. 19 except for the first process 2104 whereby a file search process is performed for finding (or enumerating) file names with the “*Hello.dll” string, the “*” symbol being the standard wild character used in string searches. A list of the games installed on each gaming terminal may be quickly and dynamically generated by calling the companion software component of the game main component instead of calling the main component itself. The companion component may be as detailed at FIG. 20 or may be a similar construct.
The embodiments of the present invention described herein are also applicable to any of the subsystems available in a network connected gaming system that require preventing non-authorized software components to execute or affect game outcome, such as the gaming terminals, the game management system (CMS or MCS) that monitor and control whole or part of the estate of gaming machines, the progressive jackpot systems, the bonussing systems as well as game payment verification systems such as IGT EasyPay and Cyberview PVU (Payment Verification Unit) and PVS (Payment Verification System). Gaming subsystems are tested against gaming standards such as those produced by GLI (Game Laboratory International); the game standards are mandated by game regulators in accordance with local regulation and laws. The network-connected subsystems may be located within the premises accommodating the estate of gaming machines (connection via a LAN) or outside of the premises (connection via a WAN).
The methods described in the document rely on software installation policies and Software Restriction Policies which may be configured (a) via the domain controller active directory, as this is advantageously the case whenever the network connection is a LAN, and which may also be configured (b) to each of the local computers via WMI services (Windows Management Instrumentation) or administrative templates (.adm files) in order to configure and enforce local group policies when a domain controller is not available as this is the case whenever the network connection is a WAN. Microsoft SMS (Systems Management Server) may be used as an alternative to using software installation policies.
The methods described in the document leverage on software installation policies and/or software restriction policies technology implemented in Microsoft Windows operating system. Whenever similar technology is implemented in other operating systems such as Linux, Unix, Windows CE and QNX, it is considered as part of the invention herein.
In an other embodiment of the invention, it order to make game regulators more at ease with the huge shift in paradigm from prehensile physically secured ROM based gaming machines (whereby access to the ROM is via multiple layers of keys locks and tamper detectors), to a totally virtual or volatile fashion of downloading game code via a network, it may be advantageous to perform download of the game code when the gaming machine is not operational. Consequently, the network downloading of game code from a central repository may not interfere with the games. This is accomplish by terminating all gaming software in order to transform the gaming machine into a generic PC, then transferring the game software under the control of the operating system using pervasive network code download available in most information technology networked environments. An “Out-of-service” message may be displayed on the screen to indicate that the machine is no longer playable, thus is no longer a gaming machine. Once the game code is downloaded by the generic PC, the game code is verified for trustworthiness and is executed, thus transforming the generic PC back into a gaming machine.
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A universal computer-implemented method for submitting source code to an authorized game certification laboratory. Initial source code and subsequent source code patches may be transferred from the manufacturer's software development environment into the laboratory's software development environment in a controlled fashion using packaging installation technology normally used for deploying software applications. The packaging technology contains automation actions for automating the synchronization and/or management of the source code and related files between the two software development environments. The entirety of the source code or any source code patch sequence may be removed by executing the corresponding uninstall function. The package containing the original source code or the source code patch sequences and related files may be code signed such as to provide persistent proof of origin which may be verified at any time. The method may be implemented under any operating system such as Microsoft Windows, Linux, UNIX and Apple Mac OS without the laboratory having to learn a complex source code configuration management software.
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BACKGROUND OF THE INVENTION
In the manufacture of certain products, notably printed circuit boards, it is important that the wall angles of the edges of laser-ablated film portions be correct. For example, if the wall angle of a via is too steep, evaporated metal will not adhere to the wall in amounts sufficient to prevent discontinuities in the electrical circuit. On the other hand, if a via has a wall angle that is too shallow, the via will occupy more space in the circuit board than is necessary.
Prior art workers have attempted to control wall angle by controlling the fluence level in the beam from the excimer laser. Typically, in the ablation process relative to an organic polymer dielectric, the threshold fluence required for ablation is approximately 70 mJ/cm 2 per pulse to 100 mJ/cm 2 per pulse. The required threshold fluence depends on the particular polymer (such as a polyimide) being ablated (reference is made to "Excimer Laser Etching of Polyimide", by J. H. Brannon, J. R. Lankard, A. I. Baise, F. Burns, and J. Kaufman, Journal of Applied Physics, Volume 58, No. 5, 1 Sep. 1985). When the fluence is raised from 1.1 times threshold to 2.0 times threshold, the wall angle increases from about 65° to about 80° from the plane of the board. However, this entire range of angles is undesirably high for the walls of vias in printed circuit boards, in that wall angles in the range of about 45° to about 50° from the plane of the board are generally regarded as optimum.
Prior art workers have also attempted to control wall angle by defocusing the projection lens, but this approach has achieved only limited success. It has been found that in order to have a wall angle of 50° or less, from the plane of the board, the projection lens must be moved far out of focus for a relatively large diameter via, but must be moved only a minor amount out of focus for a small diameter via. Thus, if openings for both large-size vias and small-size vias are required in one mask, a distinct problem is presented. In fact, if small and large openings are provided in a single mask, and the defocusing approach is employed, relatively satisfactory wall angles are provided relative to the large features, but the small or fine features are lost. Resolution capability is thus very severely affected.
SUMMARY OF THE INVENTION
The present method and apparatus are a solution to the above problem, and do not require any defocusing or any variation in the fluence level. Furthermore, the present method and apparatus are very simple and economical, being practical for mass production of parts and with minimum cost and minimum opportunity for breakdown. Control of wall angle may be achieved, with the present method and apparatus, by making either manual adjustments to the apparatus or computer-controlled adjustments thereto.
In the preferred embodiment, a thin transparent disc having parallel faces or surfaces is disposed in the path of the laser beam, and is tilted to a small angle to a reference plane that is perpendicular to the optical axis. In addition, the disc is rotated in such manner as to remain at the small angle to the reference plane. The rotation is not about the axis of the disc, but instead (preferably) about the optical axis or an axis parallel to it. Such rotation of the disc displaces each part of each pulse-generated image with respect to the same image part generated by the previous pulse of laser energy. The combination of the offset of the beam by tilting the disc relative to the optical axis, and the motion of the offset image effected by rotating the disc, achieves a highly effective and controllable way of determining the wall angle at the edge portion of a film being ablated by an excimer laser. To change the wall angle at the edge of a film, for example the wall angle of a via in a film adhered to a substrate, the angle of the disc relative to the reference plane is varied within a critical range.
In accordance with a second embodiment of the invention, a prism is employed in place of the disc having parallel faces. The nonparallel faces of the prism are caused to be at a small angle to each other. The prism is rotated, similarly to the rotation of the above-indicated disc, to cause displacement of each part of each pulse-generated image. The angle between the faces, and other factors, are such that the image is not defocused. To change the amount of displacement, and thus the wall angle at edge regions of a film, the distance between the prism and the mask is varied. Alternatively, or additionally, the amount of displacement is varied by tilting the prism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view indicating schematically- the apparatus of a preferred embodiment of the present invention;
FIG. 2 diagrammatic drawing, not to scale, showing in exaggerated generalized manner the optics of such preferred embodiment which the disc is in one tilted condition;
FIG. 2a corresponds to FIG. 2 but shows in exaggerated generalized manner the change in optics when the disc is tilted at a smaller angle relative to the reference plane;
FIG. 3 is a sectional view, on line 3--3 of FIG. 4, showing a and disc-operating mechanism;
FIG. 4 is a top plan view of the showing of FIG. 3;
FIG. 5 is a greatly enlarged vertical sectional view of a portion of a printed circuit board, indicating one of the vias, background lines being omitted for clarity of illustration;
FIG. 6 is a view corresponding to FIG. 1 but showing the prism employed in a second embodiment of the invention;
FIG. 7 is a diagrammatic drawing, not to scale, showing in exaggerated generalized manner the optics of such second embodiment when the prism is in one elevated condition; and
FIG. 7a corresponds to FIG. 7 but shows in exaggerated generalized manner the change in optics when the prism is elevated to a higher position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown in schematic form the various components of a preferred embodiment of the present invention. Thus, an excimer laser 10 is represented as being disposed to project a laser beam onto and through a mask 12, the threshold fluence relative to the mask being much greater than the fluence of the beam There is formed in mask 12 a pattern of holes and/or openings 14 It is to be understood that the indicated pattern is merely exemplary; the actual pattern may comprise any desired variety and number of locations, shapes and sizes of openings.
At the center of mask 14 is shown a round or circular hole 15 which is provided as an aid to explanation of the optics of the present system.
The portions of the beam that pass through openings 14, 15 travel through a projection lens 16 that is adapted to sharply focus the mask image on a workpiece 17. In the present example, lens 16 is 1:1. The workpiece is positioned on a worktable 18 that is adjustable in position, it being however understood that the table is not moved while workpiece 17 is being processed.
In the present illustration, workpiece 17 is a circuit board comprising a substrate having an organic polymer coating thereon as described subsequently, and from which it is desired to ablate via (or other) openings so that (for example) electrical connections may later be made to another layer of the circuit board. Various substrates may be employed, for example metallic or dielectric. The dielectrics may include (for example) ceramics with or without metal coatings. They may also include fiberglass, Kapton, Mylar, etc.
There is disposed between mask 12 and workpiece 17, preferably between such mask and lens 16, a flat transparent refracting disc 20 that is disposed transversely to the optical axis of the laser and lens system. The disc has upper and lower faces or surfaces that lie in planes parallel to each other. Disc 20 is sufficiently large, and is so located, that all portions of the beam pass through mask 12 and also pass through the disc.
The disc 20 is thin, preferably having a thickness in the range of about 1/2 mm to about 3 mm. Very importantly, disc 20 is inclined or tilted relative to a reference plane that is perpendicular to the optical axis of the laser-lens system. The combination of the disc 20 and incline causes each component of the laser beam to be refracted and thus offset, the offset being slight because of the thinness of the disc. Also because of the thinness, and because the disc is preferably formed of quartz, there is minimum absorption of ultraviolet light from the excimer laser 10.
Means are provided to rotate disc 20 about an axis that is preferably parallel to or coincident with the optical axis of the laser and lens, while at all times maintaining the disc at the same angle to the stated reference plane. In FIG. 1, the means for effecting rotation is indicated schematically as being a motor M that drives a ring 22 in which is mounted the peripheral region of disc 20, the ring being supported in bearings 23, 24. (The actual construction of a preferred embodiment of the disc-supporting, rotating and adjusting means is set forth below relative to FIGS. 3 and 4.)
It is to be understood that suitable support and adjustment means, not shown, are provided for laser 10, mask 12, bearings 23-24, lens 16, and worktable 18, and that such means hold the specified elements in desired relationships such as those indicated schematically in FIG. 1.
Very preferably, the relationships are caused to be such that the image of openings 14, 15 in mask 12 is sharply focused on the upper surface of workpiece 17.
DESCRIPTION OF THE METHOD
Proceeding first to a description of the optical portions of the preferred embodiment of the method, reference will be made to the diagrammatic, exaggerated and not-to-scale drawings of FIGS. 2 and 2a. Reference will also be made to a ray or rays passing through the center hole 15 in mask 12, such hole 15 being on the optical axis of the laser and the projection lens 16. In FIG. 2, disc 20 is shown as being inclined or tilted to a relatively large angle to the reference plane (which plane is perpendicular to the optical axis). In FIG. 2a, disc 20 is shown as being tilted to a smaller angle to such plane.
Referring first to FIG. 2, during each laser pulse a ray R passes through the center of hole 15 down the optical axis A of the system. Ray R is refracted by disc 20, and emerges from the lower face of such disc as a ray portion R1 that is offset from and parallel to the upper region of ray R. Ray portion R1 passes through the imaging lens 16, crosses optical axis A, and strikes the upper surface of substrate 17 at a point P, to perform an ablating function as described below. If the disc 20 were not present, ray R would strike substrate 17 at axis A. The amount of offsetting, of point P from axis A, which is effected by disc 20 is represented at D at the lower portion of FIG. 2. Also, the convention is adopted that such offsetting appears as a virtual image at the mask 12, the virtual image of point P being likewise offset a distance D at such mask as indicated by the dashed line at the upper portion of FIG. 2.
When disc 20 is rotated as described above, point P describes a circle on the upper surface of substrate 17, with optical axis A the center of such circle.
Referring next to FIG. 2a, the disc 20 is inclined or tilted at a smaller angle, which means that the ray portion R2 is offset a lesser distance from ray portion R and from the optical axis. Thus, the point P2 at substrate 17 is spaced a smaller distance D2 from axis A than is the case relative to the relationship shown in FIG. 2. Accordingly, when disc 20 is rotated, the point P2 describes a circle having a smaller diameter than the circle described by point P of the FIG. 2 relationship.
Proceeding next to a description of the remaining portions of the method of the preferred embodiment, the excimer laser 10 is operated to project a beam having a fluence level sufficiently high to ablate organic polymer coating material from the upper surface of workpiece 17, at places where the image of openings 14, 15 is projected. To state one example, where the organic polymer is a polyimide, the excimer laser 10 is preferably caused to deliver a beam the fluence level of which is 70 to 100 mJ/cm 2 per pulse, reference being made to the above-cited article. The pulse repetition rate may vary considerably, an exemplary rate being 300 pulses per second.
Prior to the time laser 10 is operated, quartz disc 20 is angularly adjusted to a predetermined desired angle relative to the reference plane. Such predetermined angle is selected to cause the angle of the wall at the edge of the ablated polymer to be as desired by the manufacturer, normally within the range of about 45° to about 50° from the reference plane. In addition, motor M is operated to drive ring 22 and thus disc 20 at a desired speed that is correlated to the pulse repetition rate of the laser 10. For the 300 Hz exemplary repetition rate of laser pulses, an exemplary rate of rotation of the disc 20 is 3 revolutions per second, thus causing 100 pulses to pass through the disc 20 during each rotation of the disc. It is to be understood, however, that the rate of rotation of the disc may vary widely, for example between 60 and 600.
The minimum desired rotation speed is a function of the desire to have at least one complete disc rotation during each ablation burst (typically 200 to 300 pulses). The maximum desired rotation speed results from the desire that the angular separation between pulses not be excessive. Preferably, the rotation speed and the pulse repetition rate are so correlated to each other that each ablation burst will begin and end at the same rotated position of the disc.
Because the disc is at a constant angle to the reference plane, for any desired degree of inclination of the disc and as described above relative to FIGS. 2 and 2a, the refraction effected by the disc offsets the beam a predetermined constant amount regardless of the rotated position of the disc. The image of each spot or point in those beam portions which pass through openings 14, 15 thus orbits in a small circle on the upper surface of workpiece 17, the rate of orbiting corresponding to the rate of rotation of disc 20. The radius of each orbit varies with disc inclination, as described above.
With each spot in the beam thus orbiting, the entire image of the openings 14, 15 moves accordingly-. The result is that the outer regions of the area on workpiece 17 against which is projected that beam portion which passed through mask hole 15 (for example) receive less laser pulses than do the inner regions of the workpiece area impinged against by that same beam portion.
Openings are thus ablated in the organic polymer at the upper part of workpiece 17 to form ablated regions 14a and 15a corresponding to openings 14, 15 in the mask. Each region 14a and 15a is defined by a wall at the edge of the ablated portion of the polymer, and this wall is inclined downwardly and inwardly at an angle determined by the amount of offsetting of the image (which, in turn, is determined by the angle of the disc 20 and the thickness thereof).
As an example, pulses from laser 10 will always, during each ablation burst, impinge against the workpiece 17 at the central region of the image 15a of hole 15. Conversely, pulses forming the image of the edge of hole 15 will be projected onto workpiece 17 more frequently toward the center of image 15a than they will toward the periphery of such image. Accordingly, the wall of the ablated region 15a on workpiece 17, corresponding to hole 15 in the mask, will be inclined at an angle correlated to the amount of refraction effected by disc 20.
It is emphasized that the disc 20 does not affect the fact that the beam is sharply focused on workpiece 17.
The thickness and angle of disc 20 are so selected that the amount of refraction is small in comparison to the diameters (or widths) of the openings 14, 15 in mask 12. Stated otherwise, it is not desired that the image of hole 15 (for example) travel around (in its entirety any large-diameter circle. Instead, the method provides for a small amount of refraction, the offsets D and D2 (FIGS. 2 and 2a) being sufficiently small that central regions of the image of each mask opening will be ablated more extensively than will peripheral regions thereof.
It is pointed out that the disc 20 is so thin, and the angle of the disc relative to the reference plane so small, that the amount of offset D, etc., is normally very small. Typical offsets range from 5 to 10 microns.
Referring next to FIG. 5, a metallic substrate 26 is shown as being coated on its upper surface with an organic polymer dielectric 27, for example a polyimide. The polymer 27 has been ablated by the present method and apparatus, so that a via opening 15a (an exemplary one corresponding to mask hole 15) is provided in the polymer and is sufficiently deep that the upper surface of substrate 26 is exposed. Relative to the article of FIG. 5, the polymer has been so ablated by the present invention that the wall angle of the polymer edge region or wall 31 defining the via opening 15a (for example) is at an angle between 45° and 50° to the reference plane. Where the via opening is made in response to the circular hole 15 in mask 12 (FIG. 1), the wall or edge region 31 is a downwardly convergent cone.
A via is formed by evaporating metal from a source at a distance from the workpiece 17, the distance being sufficient that the metal atoms or molecules travel substantially parallel to each other, and perpendicularly to the workpiece, when they strike the wall 31 and also strike the substrate surface portion defined within wall 31. As a result, a metal coating 32 is provided on the upper surface of the polymer both at wall 31 and around the upper region thereof, and also on the upper surface of substrate 26 defined within the bottom region of wall 31. It is to be noted that the coating is more thick at its upper and lower regions than it is on inclined wall 31.
To reduce the size of each via, the present invention is so performed that the angle of wall 31 relative to the reference plane is made somewhat smaller than is shown in FIG. 5, but not so small that sufficient metal will not adhere to wall 31.
In some processes, no conduction at all may be desired, in which case the motor M is stopped and/or the angle of disc 20 relative to the reference plane is caused to be zero.
It is to be understood that the substrate 26 is typically part of an electrical circuit pattern, and that a second layer of circuit board is provided above the upper surface of polymer 27 in electrical contact with the metal coated on such upper surface. Accordingly, electrical connection is completed between the two circuit layers by the coating 32 that is on wall 31 and near such wall.
DESCRIPTION OF PREFERRED EMBODIMENT OF THE APPARATUS
The quartz disc 20 presently employed by the inventor is 1 mm thick. It is tilted in a range of a fraction of a degree to 10°, and rotated, by apparatus described below.
Referring to FIG. 3, a suitable frame 36 receives the housing 37 of projection lens 16, both the frame and the lens housing being suitably supported by means, not shown. A variable-speed motor 38 is connected through gearing 39 to an output shaft 41 on which is fixedly mounted a pulley 42. A belt 43, for example an 0-ring, is mounted in a peripheral groove in pulley 42 and in a peripheral groove in a rotary table 44, the latter being disposed above lens housing 37 and coaxial therewith. Table 44 rotates on bearings 44a seated on a collar portion of the frame. An opening in table 44, and in frame 36, permits transmission to the lens of the laser beam.
Pivotally mounted on the upper surface of table 44 is a disc plate 45, this being illustrated as being a round flat plate having a central opening 46 in which is fixedly mounted in coplanar relationship the refracting disc 20. The pivot means comprises two balls 47 centered in the reference plane, and preferably spaced equal distances on opposite sides of the vertical central plane of the apparatus (FIG. 4). The upper region of each ball is seated in a close-fit precision opening in the underside of disc plate 45, and the lower region of each ball is seated in a precision opening in the upper surface of rotary table 44.
An adjustment set screw 48 extends through an opening in disc plate 45, opposite balls 47, being threaded in a nut 49 that is welded to the upper surface of the plate. The bottom end of the set screw 48 rests on the upper surface of the rotary table, the result being that turning of the set screw determines the angle of the disc plate relative to the reference plane. To keep everything in position, while still permitting adjustment of disc plate angle as described, two bolts 50 are extended through oversize openings in disc plate 45 and threaded into table 44, the bolts being outboard of balls 47, and being somewhat closer to set screw 48 than are the balls 47. Helical compression springs 51 are seated between the bolt heads and the upper surface of the disc plate to urge the latter downwardly at all times.
It is to be understood that the apparatus described in reference to FIGS. 4 and 5 is disposed in the system of FIG. 1 (and FIGS. 2 and 2a) between the mask and the workpiece, and preferably between the mask and the projection lens, in place of the elements 22-24 shown in such FIG. 1.
DESCRIPTION OF SECOND EMBODIMENT OF METHOD AND APPARATUS
Except as specifically stated, the second embodiment of the method and apparatus is identical to the first embodiment; accordingly, except where stated the above description applies also to the second embodiment
Referring to FIGS. 6, 7 and 7a, the second embodiment employs a prism 56 (or wedge) instead of the refractive element 20 having parallel faces. In the drawings of FIGS. 7 and 7a, the prism (and other parts) are shown diagrammatically-, not to scale and in exaggerated form. Preferably, the prism is thin, and therefore--and because it is preferably formed of quartz--absorbs very little ultraviolet light from the excimer laser.
In the illustrated embodiment, the prism has a top face that is parallel to the reference plane (which plane is perpendicular to the optical axis) and a bottom face that is inclined relative thereto. It is to be understood that either or both of the top and bottom faces could be inclined relative to such plane, provided the faces are not parallel to each other. (It is also pointed out that different-thickness discs, and in some instances different-thickness prisms, could be employed in both embodiments to change the degree of offsetting of the laser beam. This, however, is not preferred. It would also be possible, but not desired, to vary the displacement D, etc., by varying the projection lens. For example, instead of using a 1:1 lens, a 1:0.6 lens could be substituted to change the displacement accordingly.)
As shown in FIG. 7, a ray R3 from laser 10 passes through hole 15 in mask 12, along the optical axis A. Because the exemplary ray R3 is on the optical axis, and the top face of the illustrated prism 56 is perpendicular to such axis, the ray is not refracted at the top surface but only at the bottom. At the bottom surface, the ray is refracted toward the right, and passes downwardly through lens 16 and thence to the substrate 17, striking the latter at point P3. Because the prism 56 in FIG. 7 is spaced a relatively long distance from mask 12, the point P3 is spaced a larger distance from optical axis A than is the case relative to point P4 described below relative to FIG. 7a.
FIG. 7a shows the prism 56 at a relatively high elevation, substantially less spaced from mask 12 than is the case relative to the arrangement of FIG. 7. Accordingly, the ray portion R6 passing out the bottom face of prism 26 has much more space in which to deflect than is the case relative to the arrangement of FIG. 7. It follows that when the ray portion R6 reaches projection lens 16 it is spaced much farther from axis A than is the case relative to FIG. 7. The lens then bends the ray back until it strikes the substrate at point P4 that is closer to optical axis A than in the FIG. 7 situation. In FIGS. 7 and 7a, the convention is again used that a virtual image of point P3 or P4 appears at the mask.
Relative to both FIG. 7 and FIG. 7a, rotation of the prism 56, preferably about an axis parallel or coincident to optical axis A, causes the point P3 or P4 to describe a circle on the upper substrate surface, about the axis A.
As is the case relative to both of the described embodiments, all portions of the beam that pass through mask 12 describe corresponding circles, that is to say have corresponding orbits. In the second embodiment, the diameters of the circles or orbits are determined by the elevation of prism 56 as well as by the fixed characteristics of such prism--namely the angle between the two faces.
In the preferred apparatus and method relative to the second embodiment of the invention, the angle between the faces of prism 56 is made extremely small. A preferred angle is 0.01146 degree. With such a small angle, or other small angles, the amount of offsetting of the beam is very small as desired.
To state two specific examples, if the angle between the prism faces is the stated 0.01146 degree, and the distance between the lower prism face and the mask is 100 mm, the displacement D3 is 10 microns. If, however, such distance from prism to mask is reduced to 50 mm, then displacement D4 decreases to 5 microns.
The amount of offsetting effected by the prism 56 is so small that the image on the substrate 17 is not caused to become out of focus. Stated in another manner, the effect of the prism 56 is caused to be within the depth of focus of the system. Accordingly, the above-indicated disadvantages relative to defocusing of the system do not occur.
It is pointed out that the offset D3 that results when the parts are in the position of FIG. 7, or the offset D4 that results when the parts are in the position of FIG. 7a, or other offsets, could be achieved in a manner additional to moving the prism 56 upwardly or downwardly. Such prism could also be inclined, by the method and apparatus described relative to FIGS. 1-4, to achieve offsetting in a compound manner.
In the present specification and claims, the word "disc" is used only as a convenience, since such word is employed to denote a sheet of transparent quartz (or other refracting material) having any peripheral shape. If the present specification and claims, the "prism" definition is employed whereby the word denotes an optical element having two nonparallel surfaces and which is used to refract light. In the present specification and claims, the word "opening" relative to the mask denotes an optical opening, which may or may not have a transparent element across it.
The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.
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The angles of the walls of vias being ablated by excimer lasers are controlled by interposing refractive elements between the masks and the workpieces, and rotating the refractive elements about axes parallel to the optical axis. In one embodiment, the refractive element has parallel faces, and is inclined. In another embodiment, the faces of the refractive element are at a small angle to each other.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. patent application Ser. No. 09/936,319, filed on Dec. 19, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to the use of xenon for treating neurointoxications. More particularly, the present invention relates to a use of xenon in which the neurointoxication is caused by a neurotransmitter excess.
BACKGROUND OF THE INVENTION
[0003] The uncontrolled release of neurotransmitters, particularly glutamate, noradrenalin and dopamine, is responsible for many acute and chronic intoxications of the brain. These are called neurointoxications or neuropoisonings. These neurotransmitters kill the affected neurons either by induction of apoptosis (controlled cell death) and/or secondarily by their metabolites, by forming oxygen radicals which in turn have toxic effects. An uncontrolled release of neurotransmitters which result in a strongly increased concentration of the neurotoxins in the affected tissue, can be due to various endogenous or exogenous causes. For example, an increased release of glutamate or dopamine may result in an acute craniocerebral trauma. An increase in the neurotransmitter release has also been observed as a response to oxygen deficiency in the brain, e.g. in the case of apoplexy (ischemia) or in the case of other hypoxias, particularly during childbirth. Drug abuse represents another cause of impaired neurotransmitter release. In certain forms of schizophrenia, stress-induced relapses back into schizophrenia (acute episodes) are also accompanied by increased neurotransmitter release. Finally, a chronic shift of neurotransmitter balance, particularly of dopamine balance, has also been observed in various regions of the brain in the case of Parkinson's disease. Increased dopamine release and subsequent formation of free radicals occur in that case as well. Various investigations made with cell cultures and experimental animals have proven the release of neurotransmitters, particularly as a result of oxygen deficiency.
[0004] For example, it can be shown that in rats into which the dopamine neurotoxin 6-hydroxy-dopamine was infused unilaterally into the substantia nigra, which resulted in a unilateral depletion of dopamine in the ipsilateral striatum, an experimentally induced ischemia in the regions of dopamine depletion led to damage which was less than that in other regions of the brain. These results suggest that dopamine plays a part in ischemia-induced striatal cell death (Clemens and Phebus, Life Science, Vol. 42, p. 707 et seq., 1988).
[0005] It can also be shown that dopamine is released in great amounts from the striatum during cerebral ischemia (Kahn et al., Anest.-Analg., Vol. 80, p. 1116 et seq., 1995).
[0006] The release of neurotransmitters during cerebral ischemia was investigated in detail and seems to play a key role for excitotoxic neural death. For example, Kondoh et al., Neurosurgery, Vol. 35, p. 278 et seq., 1994, showed that changes in the neurotransmitter release and metabolization can reflect changes in the cellular metabolism during ischemia. The increase in the extracellular dopamine concentration in the striatum of experimental animals in which experimental apoplexies were induced, is well documented.
[0007] The contribution of excess dopamine to neuronal damage can be derived from the ability of dopamine antagonists to obtain protection of the neurons in ischemia models (Werling et al., Brain Research, Vol. 606, p. 99 et seq., 1993). In a cell culture, dopamine primarily causes apoptosis of striatal neurons, without damaging the cells by a negative effect on the oxidative phosphorylation the (ATP/ADP ratio remains unchanged). However, if its effect is combined with a minimum inhibition of mitochondrial functions, the neurotoxic effect of dopamine will be increased significantly (McLaughlin et al., Journal of Neurochemistry, Vol. 70, p. 2406 et seq., 1998).
[0008] In addition to the direct hypoxic toxicity on neurons, the stress induced by oxygen deficiency, particularly during a birth, effects an increased dopamine release, which results in a negative conditioning of the brain for dopaminergic regulations. This means that even children who seem to survive a hypoxic birth phase uninjured, have a tendency towards convulsions and epileptic conditions when they are older.
[0009] Another cause of a disturbed neurotransmitter release is represented by drug abuse. In particular, if drugs such as designer drugs (e.g. ecstasy, etc.) or heroin are consumed, and amphetamines are overdosed, the persons will show signs of intoxication and often spasmophilia, which is based on an increased neurotransmitter release.
[0010] The causes of schizophrenia are also due to a complex impairment of the neurotransmitter regulation. Schizophrenia patients are often asymptomatic over a prolonged period of time, but they have a tendency towards spontaneous schizophrenia attacks which are obviously triggered by a stress-induced dopamine release, even in minor stress situations. Here, one speaks of catatonic schizophrenia. Further neuropsychiatric diseases which are based on an increased neurotransmitter release are depressions and Gilles de la Tourette syndrome (“maladie de tics”, “Tics impulsif”).
[0011] Finally, one cause of Parkinson's disease is presently believed to be in dopamine modulation and in dopamine metabolism. In Parkinson's disease, dopaminergic neurons in the striatum are especially damaged. References exist to the effect that Parkinson's disease is caused by a dopamine excess in the affected region of the posterolateral hypothalamus and the substantia nigra. Many neurons which have lost their functionality but not their vitality are found in this region. These neurons, referred to as “orphan neurons,” continuously release neurotransmitter amounts having pathologic effects.
[0012] With the exception of Parkinson's disease, where dopa precursors are used as preparations, basically of schizophrenia, no therapeutic approaches presently exist which focus on a reduction of the dopamine concentration in the environment of endangered cells.
[0013] Therefore, there is a demand for a preparation which reduces or prevents the damaging effects of uncontrolled neurotransmitter release, e.g. of dopamine, glutamate or noradrenalin, from neurons. It is therefore an object of the present invention to provide such a preparation which can be of use in the above-mentioned, as well as in other fields of application.
SUMMARY OF THE INVENTION
[0014] In accordance with the present invention, these and other objects have now been realized by the discovery of a method for treating a mammal for neurointoxication comprising treating the mammal with a xenon-containing gas. Preferably, the xenon-containing gas comprises a mixture of gases.
[0015] In accordance with one embodiment of the method of the present invention, the neurointoxication is caused by an excess of neurotransmitter in the mammal.
[0016] In accordance with another embodiment of the method of the present invention, treating of the mammal with the xenon-containing gas comprises reducing the release of neurotransmitters in the mammal. Preferably, the neurotransmitters are dopamine, glutamate and/or noradrenalin.
[0017] In accordance with another embodiment of the method of the present invention, the neurointoxication is caused by apoplexy. In other embodiments, the neurointoxication is caused by drug abuse, oxygen deficiency during birth, a craniocerebral trauma, loss of hearing, or migraine.
[0018] In accordance with another embodiment of the method of the present invention, the neurointoxication is correlated with a condition such as Parkinson's disease, schizophrenia, or Gilles de la Tourette syndrome.
[0019] In accordance with another embodiment of the method of the present invention, the treating of the mammal with the xenon-containing gas comprises using a cardio-pulmonary bypass machine.
[0020] In accordance with another embodiment of the method of the present invention, the xenon-containing gas comprises an administered preparation containing from 5 to 90% by volume of the xenon.
[0021] In accordance with another embodiment of the method of the present invention, the xenon-containing gas comprises an administered preparation containing from 5 to 30% by volume of the xenon.
[0022] In accordance with another embodiment of the method of the present invention, the xenon-containing gas comprises an administered preparation containing a gas such as oxygen, nitrogen or air. Preferably, the xenon-containing gas comprises oxygen, and the ratio of the xenon to the oxygen is from about 80 to 20% by volume.
[0023] In accordance with another aspect of the present invention, a treatment method has been discovered comprising using xenon as a neuroprotectant.
[0024] In accordance with yet another aspect of the present invention, a method of providing neuroprotection in a mammal has been discovered, the method comprising administering to the mammal a therapeutically effective amount of xenon. Preferably, the method includes administering the xenon in combination with a compound such as a pharmaceutically acceptable carrier, diluent and/or excipient.
[0025] In accordance with another embodiment of this method of the present invention, the method includes treating the mammal for a condition associated with NMDA receptor activity.
[0026] In accordance with another embodiment of this method of the present invention, the method includes treating the mammal for a condition associated with NMDA receptor activation.
[0027] In accordance with another embodiment of this method of the present invention, the xenon reduces the level of activation of the NMDA receptor.
[0028] In accordance with yet another aspect of the present invention, a process has been provided for the preparation of a pharmaceutical composition suitable for neuroprotection, the process comprising adding xenon to a component such as a pharmaceutically acceptable carrier, excipient and/or diluent, and using the xenon as a neuroprotectant.
[0029] In accordance with the present invention, it has been found that the noble gas xenon surprisingly now reversibly suppresses the release of neurotransmitters, particularly dopamine and glutamate. This unexpected discovery has thus created the possibility of producing preparations for treating cell damage and diseases, respectively, which are caused by an increased neurotransmitter release, and particularly dopamine release or glutamate release.
[0030] Correspondingly, the present invention generally relates to the use of xenon for treating neurointoxications, and on the production of a preparation containing xenon for treating neurointoxications, respectively. The present invention also relates to the preparations per se and to a method of producing same. Such neurointoxications particularly concern an excess of neurotransmitter. The present invention is particularly based on the insight that xenon reduces the release of dopamine and/or glutamate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The present invention may be more fully appreciated with reference to the following detailed description, which, in turn, refers to the Figures wherein:
[0032] [0032]FIG. 1A is a graphical representation of the release of dopamine under various hypoxic situations;
[0033] [0033]FIG. 1B is a graphical representation of relative dopamine concentration as a result of various hypoxic situations; and
[0034] [0034]FIG. 2 is a graphical representation showing release of dopamine in various stress situations.
DETAILED DESCRIPTION
[0035] According to the present invention neurointoxications are understood to mean acute or chronic “states of poisoning” of the central nervous system (CNS), and particularly of the brain, which in most cases result in severe deficiency symptoms of the affected areas. These states of poisoning result from an excess of neurotransmitter, particularly of glutamate, noradrenalin and/or dopamine, which can be due to a variety of causes. The above-mentioned diseases, such as apoplexy, hypoxias, oxygen deficiency during a birth, Parkinson's disease, craniocerebral trauma, drug abuse, schizophrenia, depressions and Gilles de la Tourette syndrome are among those that can be mentioned here. The inventors have also found that patients who must be connected to a cardio-pulmonary bypass machine often suffer from cerebral deficiency symptoms which are due to an excess of neurotransmitter caused by hypoxia. For example, the use of a cardio-pulmonary bypass machine can cause an often unidentified neurointoxication, which delays the patient's reconvalecence to a considerable extent. It has also been found that any prolonged artificial respiration can result in undesired neurointoxication as a side-effect. In recent investigations conducted by the inventors, the surprising insight has been gained that the hearing loss (e.g. due to noise, presbycusis, tinnitus, or sudden deafness) can also be caused by neurointoxication. The excess neurotransmitter release, particularly excessive glutamate and dopamine release, which can have been caused e.g. by an impairment in the body, an acoustic trauma, or an ischemia, results in an acute destruction of the nerve endings and subsequently death of the corresponding nerves in the hearing organs. Migraine has to be considered another disease which is most likely due to an impaired dopamine balance, and thus to neurointoxication.
[0036] The discovery that the neurotransmitter release can be influenced by xenon enables an entirely new field of application for this noble gas, which has up to now been used increasingly as an inhalation anesthetic agent in the field of anesthetics. The treatment of the differing neurotransmitter excess diseases of the brain, such as those discussed above, can be carried out on the basis of the present invention by a simple inhalation therapy. The uptake of xenon by means of the respiratory system, and transport into the brain, are already proved by its use as anesthetic agent. It can also be assumed that the use of xenon has no damaging effect on the human organism, since many corresponding experiences can be realized by its use as an anesthetic agent. Xenon can be applied by various techniques, which can be chosen as a function of the location of use. For example, inhaling apparatus can be used in the clinics, which are also used for anesthesia by inhalation. If a cardio-pulmonary bypass machine or other artificial breathing apparatus is used, xenon can be added directly in the machine, and thus requires no further apparatus. In this case, standard xenon addition can prevent the formation of neurointoxications in the model case (prophylaxis) or at least reduce the deficiency symptoms. On an ambulant basis, e.g. in the primary treatment of victims of an accident, it is possible to use simpler inhalators which mix the xenon with the ambient air during the process of inhalation. In this connection, it is also possible to adapt the xenon concentration and the timing of xenon use, a in simple manner, to the therapeutic requirements. For example, it is advantageous to use mixtures of xenon with other gases, it being possible to mix the xenon with oxygen, nitrogen, air or other gases which are harmless for humans.
[0037] In patients suffering from a severe craniocerebral trauma, respiration with a xenon-oxygen mixture, as also used in anesthesia, can prevent, or at least reduce, the release of dopamine and thus the secondary neurotoxic effects accompanying this trauma. In such accidents, the additional anesthetic side-effect is desired, since the patient can be freed from pain thereby.
[0038] An essential feature of acute ischemia in the brain is represented by the secondary neurotoxic effects which form by an increase in the neurotransmitter release, and are responsible for the death of the neurons in the ischemic marginal region. Although an immediate xenon treatment, e.g. by the emergency physician who carries out the initial treatment in the case of an apoplexy patient, cannot prevent ischemia per se, but it can at least reduce, or even prevent, the neurotoxicity by the secondarily released neurotransmitters. Thus, the permanent damage frequently occurring in the case of apoplexy can be reduced. The same applies analogously to measures which will have to be taken if disease symptoms occur after drug abuse and loss of hearing, or a migraine attack.
[0039] In the case of oxygen deficiency during a birth, e.g. during the entrance into the obstetric canal or in the case of problems with the umbilical cord, xenon-(oxygen) respiration of the mother and respiration of the child as soon after the birth as possible, respectively, can prevent the negative effects of increased dopamine release during the oxygen deficiency.
[0040] In the case of schizophrenia, patients suffer from periodic schizophrenia (catatonia), the progress is very sudden, the picture of the state being characterized by dramatic symptoms which show varying pictures and are full of delusions and hallucinations. Often a phase disappears as rapidly as it started. Such phases or attacks can be triggered spontaneously by stress situations. Rapid respiration with a xenon gas mixture during the state of stress can at least reduce the intensity of the attack. For this application, it is an obvious thing to equip patients with xenon inhalators which permit self-medication.In this case, it is conceivable to use containers which, similar to asthma sprays, are filled with xenon which will be released if a trigger is pressed. The same applies analogously to the treatment of depressive patients whose moods change almost daily and who as a result thereof require state-related medication.
[0041] Chronic Parkinson's disease is accompanied by progressive symptoms. A consequent xenon treatment reduces the neurotransmitter release and slows down the progression, or even brings the progression of the disease to a stand-still. In this case, intermittent treatment offers itself in which the patient is respirated with xenon at certain intervals. The same applies to patients who suffer from the Gilles de la Tourette syndrome. Their tics also become more and more distinct as the disease proceeds.
[0042] In the case of acute threatening states, such as a craniocerebral trauma or an ischemia, respiration can advantageously be carried out with a xenon-oxygen mixture of 90:10% by volume, preferably 80:20% by volume, and most preferably 75-70:25-30% by volume, over several hours to one day. As compared thereto, the intermittent respiration by a xenon-air mixture to which less xenon has been added, e.g. 5 to 30% xenon, preferably 10 to 20% xenon, can be considered in chronic progressions of a disease.
[0043] Various methods for the inhalation of xenon and xenon mixtures, respectively, can be used which depend on the respective intended use. In clinics, it is possible to use anesthetic apparatus, in which prefabricated xenon-oxygen mixtures can be connected to the corresponding inlets of the anesthetic apparatus. Respiration is then carried out according to a procedure which is common for such apparatus. The same applies analogously to the cardio-pulmonary bypass machine.
[0044] As an alternative, xenon can be mixed with ambient air instead of oxygen in the mobile use, which due to the smaller size of the required pressure bottles increases the mobility of the apparatus. For example, it is possible to use an inhalator which supplies xenon from a pressure bottle and is accommodated in a support, together with the latter, to a mixing chamber. On one side, this mixing chamber contains a mouthpiece for inhaling the xenon, and on the other side on which the xenon is supplied to the mixing chamber it has at least one additional check valve which enables the inlet of ambient air. The xenon pressure container can be equipped with a pressure reducing valve, for example, which reduces the amount of xenon gas supplied to a suitable value. When the patient breathes in, he sucks in air from the air valves. In the mixing chamber, this air is mixed with the supplied xenon to the desired ratio and then inhaled by the patient. An advantageous inhalator intended for mobile use and serving for inhaling xenon and its mixtures is shown in, for example, European Patent No. 560,928.
[0045] In a further simplified embodiment, e.g. for self-medication, a mouthpiece is connected directly to the xenon pressure container. During inhalation, the patient opens the pressure valve and inhales xenon simultaneously with the air from the environment. When he breathes out, he releases the valve, so that no more xenon reaches the mouthpiece. In this manner, at least a coarse regulation of the amount of inhaled xenon is possible.
[0046] The present invention is explained in more detail below, reference being made to attached FIGS. 1 and 2, which show the dopamine release in cell cultures exposed to hypoxic shock.
[0047] The function of the present invention shall be explained in more detail below by means of the following examples.
EXAMPLE 1
[0048] An in vitro experiment with PC12 cells is concerned. These PC12 cells are dependants of a pheochromocytoma of rats. Here a catecholamine-producing tumor of the suprarenal cortex is concerned, which shows permanent dopamine release in a malignant form. PC12 cells can be reproduced continuously in vitro. Following the addition of “nerve growth factor”, they start differentiating and become neurons which in many respects have the property of in vivo neurons, particularly the properties which relate to the neurotransmitter release. PC12 cells are acknowledged as neuronal model.
[0049] PC12 cells differentiated in such a manner when exposed to a hypoxic situation, release dopamine. Such a hypoxic situation is an artificially induced stress state for the cells, in which e.g. the oxygen supply is dropped or impeded. If the cells are treated under these hypoxic conditions with xenon in defined concentrations over the same period of time, the neurotransmitter release will be dropped. The time course of such an experiment is shown in FIG. 1 by way of example. The curve of the non-stressed controls, illustrated by solid squares, shows a low dopamine concentration throughout the time course, which is subject to certain fluctuations. If a hypoxic situation is triggered by a dose of helium instead of oxygen, the curve of the dopamine concentration will result as shown in the curve produced from the solid triangles. A maximum dopamine concentration is shown in this case after about 40 minutes. However, if xenon is given in a hypoxic situation, the cells will virtually no longer differ from the control cell population, as shown by the plot illustrated by solid circles. In connection with the relative dopamine concentration shown in part B of FIG. 1 it can also be clearly seen that the dopamine release is reduced down to values of the control cells. In this connection, it was found that the xenon effect is fully reversible, so that the cells treated in this way cannot be distinguished from untreated cells after the xenon is washed out. In the above-described experiment, the gases used were given to the cells by mixing them with the growth buffer for the cells. In this case, saturated gas buffer solutions are involved.
EXAMPLE 2
[0050] The differentiated PC12 cells described in Example 1 were distributed to various vessels and exposed to differing conditions. The results are shown in FIG. 2. These conditions are defined as follows:
Control: incubation in normal atmosphere (ambient air) N2: incubation in nitrogen (N2) for 30 minutes [= hypoxia] Xenon: incubation in xenon for 30 minutes Glu: addition of 10 M glutamate for 30 minutes of incubation in a normal atmosphere Glu + N2: addition of 10 M glutamate for 30 minutes of incubation in N2 Glu + Xe: addition of 10 M glutamate for 30 minutes of incubation in xenon.
[0051] A hypoxic condition and an increased release of dopamine resulted in the cells incubated with nitrogen (group: N2). The dopamine release may even be increased if, in addition to the nitrogen atmosphere, glutamate, which represents a neurotransmitter and has a neurotoxic effect in greater doses, was given as well (group: Glu+N2). However, if 10 M glutamate was given in the simultaneous presence of xenon (Group: Glu+Xe), a slightly increased dopamine release would still result, but which was nevertheless reduced by two-thirds as compared to the corresponding (glutamate+N 2 ) experiment.
[0052] The results shown in FIG. 2 demonstrate that in stress situations such as hypoxia, the neurotransmitters glutamate and dopamine are released in large quantities. This results in a) direct damage to the neighboring neuronal tissues, mainly by inducing apoptosis and b) indirectly, an additional increased release of other neurotransmitters. Thus, the addition of glutamate to the cells effects an increased dopamine release, particularly when the cells are kept under hypoxic conditions. The unintentional neurotransmitter release could be reduced many times over by the simultaneous supply of xenon.
[0053] It can therefore be shown, on an overall basis, that in the present invention xenon can stop rapidly and without other permanent side-effects the neurotransmitter release temporarily. Hence it follows that xenon can be used in defined concentrations in a therapeutically useful manner in all pathologic conditions characterized by unregulated neurotransmitter release. The simple application by inhalation and the harmlessness of xenon render this therapy especially attractive. Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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Methods for treating mammals for neurointoxication are provided comprising treating the mammal with a xenon-containing gas. Methods of providing neuroprotection in mammals are also disclosed comprising administering therapeutically effective amounts of xenon, preferably in combination with pharmaceutically acceptable carriers, diluents or excipients.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hydrogen storage electrode for use as an anode of an alkaline battery, and also to a process for producing the same.
2. Description of the Prior Art
Process for producing a hydrogen storage electrode can be grouped roughly into two methods according to whether or not sintering is applied in the process. Namely, one is sintering method as described, e.g., in Publication of Unexamined Japanese Patent Application No. 1-132048 (1989), according to which hydrogen storage alloy powder set in contact with an electric current collector is bonded together by sintering under a temperature of about 1,000° C. while the former alloy powder is held pressed against the latter current collector.
The other is non-sintering method as disclosed, e.g., by Publications of Unexamined Japanese Patent Applications No. 2-278659 (1990) and No. 3-98261 (1991). According to this method, hydrogen storage alloy powder is mixed with copper powder which amounts to about as many as 4 to 5 times by weight as the alloy powder and serves as a conductivity aid, and the mixture is pressed onto a current collector for bonding thereby to form a hydrogen storage electrode. Alternatively, the mixture of the hydrogen storage alloy powder and the conductivity aid may be mixed further with a binder such as fluororesin powder and then pressed and bonded to a current collector in the atmosphere of about 300°.
It is noted, however, that the production process according to the sintering method is complicated and hence costly and also that the hydrogen storage electrode made in the non-sintering method is poor not only in conductivity, but also in the mechanical bonding strength between particles of the hydrogen storage alloy powder and also between the alloy powder and the current collector.
According to the non-sintering method in which a large amount of conductivity aid is used, discharge capacity per given weight or volume of the resulting electrode will be reduced, and the use of fluororesin as a binder will increase the internal electrical resistance of the electrode. If only a less amount of binder is added with an attempt to prevent such an increase of the resistance, it will affect the mechanical bonding strength and hence the charge and discharge cycle life of the electrode. Additional heating to a substantially high temperature may be performed to secure the bonding strength, but only at the sacrifice of additional cost.
SUMMARY OF THE INVENTION
It is an object of the present invention, therefore, to provide a hydrogen storage electrode which can present excellent capabilities of the discharge capacity and the charge and discharge cycle life when it is used as an anode of a alkaline battery and also a process for manufacturing such electrode without complicating the production.
The process for producing a hydrogen storage electrode according to the present invention includes steps of preparing hydrogen storage alloy powder with maximum particle size of 50 μm, plating the alloy powder with copper amounting to 10% to 20% by weight with respect to the sum of the alloy powder and the plating copper, and pressing the copper-plated alloy powder and an electric current collector set in contact therewith for bonding to such an extent that the porosity of the compact of the alloy powder in the resulting electrode falls in the range of 10% to 25%.
A battery with a hydrogen storage electrode made of alloy powder whose maximum particle size was greater than 50 μm offered only a shorter cycle life.
The cycle life of a battery with an electrode whose copper plating was less than the above 10% by weight was disadvantageously short, and a battery with an electrode whose copper plating was greater than the above 20% by weight showed a poor discharge capacity.
The discharge capacity of a battery was lower when the porosity of its electrode was less the above 10% and the cycle life was shorter when the porosity was more than the above 25%. The porosity is defined as the ratio of porous volume of the copper-plated alloy powder compact to the volume of that compact.
The hydrogen storage electrode according to the invention can be produced more easily than those electrodes which have been made by the above conventional sintering method or non-sintering method using fluororesin as binder. Additionally, a battery using the electrode made by the process of the invention was found to offer better characteristics in the discharge capacity and cycle life than a battery using a conventional electrode containing fluororesin as binder and a large amount of copper as conductivity aid.
It is presumed that the ductility of copper used for plating the hydrogen storage alloy powder can help to achieve intimate contact of powder particles and to increase the bonding strength between the powder particles and also between the alloy powder and the electric current collector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the cycle lives of batteries with hydrogen storage electrodes made according to the first embodiment in which alloy powders of different particle size distributions were used.
FIG. 2 is a graph showing the cycle lives of batteries with hydrogen storage electrodes made according to the second embodiment in which alloy powders with different copper plating amounts in percentage by weight were used. The graph also provides the cycle lives of batteries with electrodes without copper plating, but containing a predetermined amount of copper, nickel and carbon powder, respectively, as conductivity aid.
FIG. 3 is a graph showing the cycle lives of batteries with hydrogen storage electrodes made according to the third embodiment in which alloy powders were pressed into compacts to different porosities.
FIG. 4 is a graph showing the cycle lives of batteries with the same hydrogen storage electrodes made according to the third embodiment, but containing a different copper plating amount in percentage by weight.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following will describe preferred embodiments of the hydrogen storage electrode and the process for producing such electrode.
1. First Embodiment
Hydrogen storage alloy having the composition of MmNi3.5Co0.7Al0.8 was mechanically pulverized into particles of powder. Then, passing the particles of alloy powder through standard sieves with four different meshes 150×150 μm, 105×105 μm, 50×50 μm and 20×20 μm, the alloy powder was sorted into four different powders according to the maximum nominal particle size of each powder in order to make four different electrodes "A"-"D" which will be specified hereinafter. It should be noted that some particles slightly larger than the nominal size defined by the sieve mesh may be included in each alloy powder because of inevitable inaccuracy of each sieve mesh.
Then, the alloy powder was made into microcapsules by electroless plating with copper amounting to 10% by weight with respect to the sum of the alloy powder and the plating copper.
After the copper-plated alloy powder was dried sufficiently, a predetermined amount of the copper-plated alloy powder was put in a layer into a cavity formed in a stationary lower die of a molding press and having a shape conforming to an electrode to be made. An electric current collector made of nickel expand metal was placed on the layer of copper-plated alloy powder in the cavity, and then the press dies were closed to cold-press for bonding the copper-plated particles of powder together into a compact, as well as the current collector to the compact. This cold pressing resulted in an electrode in process with a size of 40×30 mm, a thickness of 0.6 mm and a porosity of 25%. Using the above method, four kinds of electrodes in process were provided which included alloy powder with different maximum particle size. For the sake of reference, these electrodes made of powders with maximum particle sizes 150 μm, 105 μm, 50 μm and 20 μm were named as "A", "B", "C" and "D", respectively. Incidentally, the porosity of the compact was figured out as follows. Firstly, the volume of the nickel expand metal (or weight/specific gravity) was subtracted from the electrode volume to find the volume of copper-plated alloy powder, and the weight of the alloy powder was found by subtracting the expand metal weight from the electrode weight. Then, the specific gravity of the copper-plated alloy powder, as obtained by dividing its weight by its volume, was divided by the theoretical specific gravity of the copper-plated alloy powder to find the porosity.
Each of these electrodes in process was assembled to a sintered nickel cathode having a sufficiently large capacity with a non-woven nylon fabric held therebetween and the assembly was immersed in an electrolyte of potassium hydride solution having a specific gravity of 1.26. Thus, a negative pole limited battery was made. After the electrode was activated sufficiently by repeating charging at 0.4 CmA for three hours to 120% charge and discharging at 0.2 CmA to a cut off voltage of 0.8V under a temperature of 20° C., the discharge capacity per electrode volume was measured. Subsequently, after the electrode was activated, charging at 0.4 CmA for three hours to 120% charge and discharging at 0.4 CmA to a cut off voltage of 0.8V were repeated under a temperature of 20° C. to determine the cycle life of each electrode.
TABLE 1______________________________________Discharge capacity per electrode volumeElectrode Discharge Capacity (mAh/CC)______________________________________A 830B 870C 950D 960______________________________________
TABLE 1 provides the discharge capacities per electrode volume of batteries with the electrodes "A"-"D", respectively, and FIG. 1 shows the cycle lives, i.e., the rate at which the battery capacity is decreased with an increasing number of charge/discharge cycles.
As it is apparent from TABLE 1, the smaller the particle size is, the higher the discharge capacity per electrode volume is. Microscopic observation of electrode surface revealed that particles of 60 μm or more of the copper-plated alloy powder was cracked after the alloy powder was pressed to the electric current collector. It can be thought that the cracks found in the electrodes made of alloy powder of larger particle size were responsible for poor conductivity and hence a lower discharge capacity of batteries having such electrodes.
It was presumed that an increase of copper plating amount over 10% by weight would make the electrode less susceptible to such cracking.
It was presumed also that a decrease of the porosity below 25% by application of a stronger pressure in the pressing operation would improve the mechanical bonding strength of the copper-plated alloy powder and the electrode would be made less susceptible to cracking, accordingly.
As seen from FIG. 1, batteries with the electrodes "A" and "B" exhibited a noticeable drop in the capacity in the cycle life testing, as compared with batteries with the electrodes "C" and "D" made of smaller-size powder particles. It can be thought that, with the electrodes "A" and "B", the alloy particles tended to become finer by the repeated charge and discharge cycles, which resulted in deterioration of the holding strength of the bonded alloy particles and hence allowed part of the particles to come off from such electrodes.
2. Second Embodiment
In the second embodiment of the hydrogen storage electrode, four different electrodes were prepared which were made in the same method and had the same alloy composition as the electrodes "A"-"D" in the first embodiment, but differed therefrom in that the maximum nominal particle size of the alloy powder was 50 μm only and the copper plating was applied with different percentages by weight. Namely, 5%, 10%, 20% and 25% by weight of copper were plated to the alloy powders and the resulting electrodes were referred to as "E", "F", "G" and "H", respectively.
As specimens intended for comparison with these electrodes "E"-"H", three different hydrogen storage electrodes "I"-"K" were prepared which were free from copper plating, but mixed with 20% by weight of conductivity aid. The electrodes mixed with copper powder, nickel powder and carbon powder as the conductivity aid were labeled as "I", "J" and "K", respectively. All the electrodes "E"-"K" were formed to the same 25% porosity.
Using these electrodes "E"-"K", testing was conducted to determine the discharge capacity per electrode volume and the cycle life in the same methods as used in the first embodiment. TABLE 2 shows the discharge capacities and FIG. 2 the cycle lives of batteries with the electrodes "E"-"K", respectively.
TABLE 2______________________________________Discharge capacity per electrode volumeElectrode Discharge Capacity (mAh/CC)______________________________________E 1100F 1080G 930H 880I 580J 720K 550______________________________________
For the sake of further comparison with the electrodes "E"-"H", hydrogen storage electrodes of the same alloy composition were made in the same method as the above electrodes "E"-"K", but using alloy powders with particle size of 20 μm or less. The testing results of these electrodes showed substantial no difference from those obtained from testing the electrodes "E"-"K".
As seen clearly from TABLE 2 and FIG. 2, batteries with the electrodes "I"-"K" showed less discharge capacities per electrode volume and shorter cycle lives than batteries with the electrodes "E"-"H". It can be thought that such discharge capacity and cycle life resulted from poor mechanical bonding strength between the alloy powder particles and poor conductivity in the electrodes "I"-"K", which affected the cycle life and the discharge capacity, respectively, in contrast to the electrodes "E"-"H" in which ductile layers of copper plating were pressed into intimate contact with each other to thereby wrap and hold the alloy powder particles securely, thus improving the conductivity.
With reference to the electrode "E" having 5% by weight of copper plating, however, its smaller copper-plating amount resulted in poor contact between the powder particles and hence shorter cycle life, although it provided good characteristics in the discharge capacity. With the electrode "H" having 25% by weight of copper plating, on the other hand, its larger amount of copper reduced the discharge capacity.
3. Third Embodiment
In still another embodiment of the hydrogen storage electrode, four different electrodes "L", "M", "N" and "P" were prepared which were made of the hydrogen storage alloy powders of the same composition and in the same method as the electrodes "A"-"D" in the first embodiment, but differing therefrom in that the maximum particle size was 50 μm only, 20% by weight of copper plating was applied, and also that the alloy powders were pressed to porosities 8%, 10%, 25% and 30%, respectively. Using these electrodes "L"-"P", testing for the discharge capacity per electrode volume and the cycle life was conducted in the same methods as in the first embodiment. TABLE 3 shows the discharge capacities per electrode volume and FIG. 3 provides the cycle lives of these electrodes, respectively.
TABLE 3______________________________________Discharge capacity per electrode volumeElectrode Discharge Capacity (mAh/CC)______________________________________L 760M 910N 930P 830______________________________________
Furthermore, four different hydrogen storage electrodes "Q"-"T" were made of the same alloy composition and in the same method as the above electrodes "L"-"P", but with 10% by weight of copper plating and different porosities of 8%, 10%, 25% and 30%, respectively. These electrodes were tested to determine the discharge capacity and the cycle life in the same method as in the first embodiment. FIG. 4 shows the discharge capacities per electrode volume and TABLE 4 shows the cycle lives of these hydrogen storage electrodes "Q"-"T", respectively.
TABLE 4______________________________________Discharge capacity per electrode volumeElectrode Discharge Capacity (mAh/CC)______________________________________Q 880R 1050S 1080T 870______________________________________
As apparent from FIGS. 3, 4 and TABLES 3, 4, the electrodes "M" and "R" with the porosity of 10% and the electrodes "N" and "S" with the porosity of 25% exhibited excellent characteristics both in the discharge capacity and the cycle life. This is because the electrodes with 10% or less porosity allow only a smaller amount of electrolyte to permeate thereinto and, therefore, the contact between the electrolyte and the alloy powder and hence the effective reaction area becomes less, with the result that the utilization of the alloy powder was reduced. With the electrodes with 25% or more porosity, on the other hand, the electrode volume is larger and the bonding area between the powder particles is less, so that the electric resistance becomes higher and the mechanical strength of the electrode poor, with the result that the discharge capacity and the cycle life are reduced.
While the invention has been described with reference to the specific embodiments, it is to be understood that the present invention can be practiced in various changes and modifications without departing from the spirit or scope thereof, as exemplified below.
Cold-pressing for bonding of the hydrogen storage powder and the electric current collector in the above-described embodiments may be substituted with hot-pressing.
Though molding of the electrode is accomplished by mechanical pressing the copper plating layers, without using conductivity aid or binder, in the above embodiments, a small amount of conductivity aid or binder may be added. Nickel or copper powder may be used as the conductivity aid, and PVA (polyvinyl alcohol), CMC (carboxymethyl cellulose) or PTFE (polytetrafluoroethylene) may serve for the purpose of binding.
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A hydrogen storage electrode for use as an anode of an alkaline battery and a process for producing such electrode are disclosed. According to the process, firstly particles of hydrogen storage alloy powder with maximum particle size of 50 μm is prepared. The alloy powder particles are then made into microcapsules by electroless plating with copper amounting to 10%-20% by weight with respect to the sum of the alloy powder and the plating copper. With an electric current collector placed in contact with the copper-plated alloy powder set in a die cavity of a molding press, the molding dies are closed to press and the copper-plated powder and the current collector for bonding them together thereby to form the hydrogen storage electrode. Pressure exerted during the pressing is applied to such an extent that the porosity of the resulting compact of the pressed alloy powder falls in the range of 10% to 25%.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved expanded sheet reinforcing material and more particularly to an expanded formable sheet material having a layer of a foamable adhesive adhered to selected surfaces, to methods of manufacturing such expanded sheet material, to methods of reinforcing articles and articles reinforced with such sheet reinforcing material.
2. Description of the Prior Art
Expanded formable sheet material is well-known and widely used for a variety of purposes and apparatus is commercially available for making such expanded sheet material either in a continuous or intermittent operation. In the continuous type of expanding apparatus, an elongated sheet or strip of formable material, for example sheet plastic, steel, aluminum, copper, or other formable material sometimes referred to hereinafter generally as structural sheet material, is fed past a slitting station where a series of parallel, laterally spaced, longitudinally off-set rows of slits are formed through the sheet. The slit sheet is then expanded, or stretched, in a direction transverse to the direction of movement through the apparatus to separate or open the slits. The expanded sheet material may then be coiled or cut into individual sheets, as desired.
The intermittent process, widely used in the production of expanded sheet metal, involves the use of a die having a plurality of spaced shearing sections or teeth which form the slits by shearing the sheet transverse to its width and simultaneously press the sheared portions of the metal downwardly out of the plane of the unsheared sheet to expand the metal. After each shearing and forming stroke, the die is retracted and either the die or the sheet is moved laterally and the sheet is indexed forward before the next shearing and expanding stroke of the die. This intermittent sheet expanding method, preferred in the practice of the present invention, is generally disclosed in U.S. Pat. Nos. 1,448,109 and 1,561,272.
Various configurations of the die can be used in the intermittent apparatus to provide various shapes of openings as well as different configurations of the strands and joints in the expanded material, though the conventional expanded metal is formed with generally diamond-shaped openings defined by substantially straight-sided strands and joints. In the description of the present invention, the openings will be referred to as generally diamond-shaped, it being understood that the exact configuration is not critical and that such description is intended to include openings of various configurations defined by the interconnected strands and joints.
It is known to employ expanded sheet metal as a stiffener or reinforcing laminate for articles made of sheet metal by attaching the expanded material directly to a surface of the sheet. This concept is shown, for example, in U.S. Pat. No. 2,349,907 wherein flat-rolled expanded sheet metal is spot welded to one surface of a thin sheet metal structural element such as the inner surface of a door panel of an automobile to provide a composite structure having increased stiffness and higher strength than available from flat sheet metal of equal weight.
U.S. Pat. No. 2,820,228 discloses the use of expanded metal to reinforce and stiffen the bottom of a drawn sheet steel bathtub. The reinforcing is rigidly secured to the outer surface of the bottom panel by welding before the usual enamel coating is applied. Again, the expanded metal reinforcing material is rolled to lie flat against the bottom of the tub, and the two metal components are stated to be preferably rigidly joined throughout substantially their entire contact area, although the patent also states that spot welding can be used if the spot welds are sufficiently close to preclude relative movement upon flexing of the bottom of the tub.
While flat-rolled expanded metal has been used as a reinforcing and stiffening laminate for thin sheet metal as disclosed in the above mentioned patents, substantial bending strength, or stiffening ability, may be lost by rolling the expanded metal to the flat state. This may be particularly true for expanded sheets in which the width of the individual strands, i.e., the distance between successive shear lines formed in the material, is substantially greater than the thickness of the original sheet material. When unflattened or unrolled expanded metal is laminated onto a smooth surface, the strands and joints are disposed at a relatively large, acute angle to the cover sheet making the effective thickness of the laminated structure substantially greater than the combined thickness of the cover sheet and the thickness of the sheet material from which the expanded sheet was formed.
Expanded sheet material, as formed on commercial expanding equipment generally has not met widespread use as a stiffening or reinforcing laminate for continuous thin sheets. This is believed to be due, at least in part, to the configuration of the expanded metal which only permits a very small surface area contact between such an expanded sheet and a continuous surface. Such contact is limited to the inclined sheared edges of the joint portion of the expanded metal only, with the edges of the individual strands being spaced from the continuous surface. This limited contact makes effective spot welding or joining by other conventional means very difficult.
U.S. Pat. No. 2,371,754 discloses the concept of stiffening a lightweight, thin sheet material by attaching a uniform pattern of wire to one surface of the sheet of material This patent discloses various forms of welding for attaching the reinforcing wires to the surface of the sheet, and also suggests cementing the wire to the sheet; however, neither the nature of the cement contemplated nor the manner of applying it are disclosed. It is noted, however, that the reinforcing wires are fused together where they are crossed so that, as in the case of the flat-rolled expanded sheet, the wires lay in direct surface-to-surface contact with the sheet metal throughout their full length.
SUMMARY OF THE INVENTION
According to the present invention, an expanded sheet reinforcing material is provided which can readily be secured directly to a continuous surface, for example, the surface of a continuous sheet constituting a portion of a structural panel or the like. The reinforcing sheet is a composite structure consisting of an expanded structural sheet material having one face of the strands and joints coated with an adhesive material which may be activated to expand or increase its volume as by foaming to firmly bond the expanded sheet to a contiguous surface. The adhesive used is preferably of the type which is normally in a stable, self-supporting, non-tacky condition so that it can readily be handled, and which is sufficiently resilient to enable the adhesive and expanded base material to be formed as necessary to conform to a surface to which the reinforcing sheet is to be attached.
In order to avoid confusion of terms, the adhesive material employed in the present invention will be referred to as a foamable or foaming adhesive, it being understood that this term is intended to include any form of volume expansion, whether or not accomplished by an actual foaming action. Similarly, the terms "expanding" or "expanded" are used herein to refer to the process of spreadng or extending the lateral expanse of a sheet material as in the well established expanded metal art.
The expanded reinforced sheet material according to this invention may be formed by bonding an adhesive in sheet form, e.g., a preformed sheet of rubber based adhesive, directly to one surface of a formable high-strength sheet material such as sheet or strip steel. The adhesive-structural sheet laminate can then be passed through an expanding apparatus and the composite expanded in the conventional manner for forming expanded sheet metal.
Heat-activated foamable rubber based adhesive material which expands, bonds and seals upon exposure to moderate heat, for example, heat within the range of about 250° F. to 375° F., is commercially available in sheet form. The volume expansion of such commercially available adhesive may be up to 150% or more, depending upon the time of exposure to and intensity of the activating heat. Such a foamable adhesive sheet may be permanently bonded to the structural sheet base by initially heating the structural sheet and pressing the sheet of adhesive material into firm contact with the heated sheet by passing the two through a pair of pinch rolls. The heat in the structural sheet is controlled to be sufficient to activate the surface portion only of the adhesive sheet to produce a firm bond. The laminated structure may be quickly cooled to prevent excessive activation and foaming of the adhesive material.
The structural strip--foamable adhesive laminate can then be passed directly into a metal expanding apparatus, preferably of the intermittent type referred to above, where the composite is simultaneously slit and shaped so that one face of all of the joints and strands are completely covered with the adhesive after the forming operation. The expanded structural sheet thus formed can be handled in the conventional manner for expanded metal, for example, by rolling into coils or cutting into sheets. Preferably, a separator sheet of suitable paper or the like is deposited on the surface of the formed matrix before coiling or stacking to minimize the likelihood of damage or disruption of the adhesive layer.
In an alternate embodiment of the invention, a suitable adhesive material is laminated between two structural sheets, or strips, and the laminated composite then passed through the expanding apparatus so that the foamable adhesive is confined between the opposed surfaces of adjacent strands and joints of the two expanded structural sheets. Upon activation, the foamable adhesive is extruded out from between the confining structural sheet components to engage and form a firm bond with an adjacent surface. This embodiment of the reinforcing material may be utilized as a spacing core between two cover sheets, with the core acting to firmly adhere the two sheets together to provide a lightweight high-strength honeycomb-type sandwich structure.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become apparent from the detailed description contained hereinbelow, taken in conjunction with the drawings, in which:
FIG. 1 is a perspective view of a fragment of a sheet of expanded metal formed on conventional metal expanding apparatus;
FIG. 2 is a view similar to FIG. 1 and showing a fragment of an expanded reinforcing sheet according to the present invention;
FIG. 3 is an enlarged sectional view taken on line 3--3 of FIG. 2;
FIG. 4 is a schematic view showing an apparatus for forming the reinforcing structural sheet according to the present invention;
FIG. 5 is a perspective view schematically showing an intermittent type sheet metal expanding apparatus being utilized to form an expanded reinforcing sheet according to the present invention;
FIG. 6 is an enlarged perspective view of a portion of the apparatus shown in FIG. 5;
FIG. 7 is a fragmentary perspective view of a section of reinforcing sheet material according to the present invention bonded to a cover sheet;
FIG. 8 is an enlarged sectional view taken on line 8--8 of FIG. 7;
FIG. 9 is an enlarged sectional view taken on line 9--9 of FIG. 7;
FIG. 10 is a schematic illustration of an apparatus for forming an alternate embodiment of the expanded reinforcing sheet according to the present invention;
FIG. 11 is an enlarged sectional view taken on line 11--11 of FIG. 10;
FIG. 12 is a perspective view of a fragment of a reinforcing sheet formed on the apparatus of FIG. 10;
FIG. 13 is an enlarged sectional view taken on line 13--13 of FIG. 12;
FIG. 14 is a view similar to FIG. 7 and showing a sandwich type reinforcing sheet bonded to the surface of a continuous cover sheet;
FIG. 15 is an enlarged sectional view taken on line 15--15 of FIG. 14;
FIG. 16 is an enlarged sectional view taken on line 16--16 of FIG. 14;
FIG. 17 is a fragmentary perspective view, with portions broken away, of a sandwich type reinforcing sheet material laminated between two structural cover sheets;
FIG. 18 is an enlarged fragmentary sectional view taken on line 18--18 of FIG. 17; and
FIG. 19 is an enlarged fragmentary sectional view taken on line 19--19 of FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, a fragment of an expanded sheet of formable structural material, typically sheet metal, is shown in FIG. 1 and designated generally by the reference numeral 10. The expanded sheet 10 is made up of a plurality of staggered rows of elongated sheared strands 12 joined together by integral connecting joints 14, sometimes referred to as bonds or bridges, with the strands and joints cooperating to form a uniform pattern of generally diamond-shaped openings 16. The expanded sheet 10 is conventionally formed from a continuous sheet or strip of relatively thin flat-rolled metal, utilizing commercially available expanding apparatus in which staggered rows of strands 12 are cut from the sheet by a slitting or shearing operation depending upon the type of apparatus employed. In the practice of the present invention, it is preferred to employ the intermittent type of forming apparatus in which the flat sheet is fed in intermittent increments through the apparatus, with each increment of feed corresponding to the width of the individual strands 12, this width being indicated by the opposed arrows at 18 in FIG. 1, and the width of the joints being double the width of the individual strands. The thicknss of the strands and joints is, of course, substantially equal to the thickness of the original structural sheet from which the expanded sheet is formed. Preferably the strand width is at least equal to the original sheet-metal thickness and may be several times the metal thickness. An increase in strand width results in a corresponding overall reduction in metal expansion. As a general rule, strand width will not be more than about six times the metal thickness.
Referring now to FIGS. 2 and 3, an expanded reinforcing sheet according to the present invention is illustrated as comprising an expanded structural sheet 19 of the type shown in FIG. 1 with a coating 20 of foamable adhesive firmly bonded directly to the face of each strand and joint on one side of the sheet. The adhesive coating 20 is a continuous coating, completely covering the surface portions of the expanded metal sheet 19 which, before expanding, constituted one face surface of the structural sheet.
Apparatus suitable for forming an expanded reinforcing sheet according to the present invention is schematically shown in FIGS. 4-6. As illustrated, a running length or strip 22 of flat, relatively thin structural material, for example flat-rolled steel in strip form, is fed from a coil 24 by a pair of driven pinch rolls 26. From rolls 26, strip 22 passes beneath a hood 28 housing suitable heating means such as the infra-red heater 30 spaced closely above the top surface of the strip 22. As the heated strip 22 emerges from beneath hood 28, a temperature sensor 32 senses the temperature of the top surface of the strip. Sensor 32 is connected in a suitable control circuit for heater 30 to maintain the surface temperature of strip 22 at the desired level for reasons described more fully hereinbelow.
Immediately after passing beneath the temperature sensor 32, strip 22 passes through the nip of a pair of silicon rubber-covered pinch rolls 34 which cooperate to firmly press a preformed sheet 36 of a suitable adhesive such as a rubber based, heat activated foamable adhesive onto the top surface of the heated strip 22. The adhesive sheet 36, in continuous strip form, is fed from a roll 38 supported above the path of the strip 22.
The temperature of strip 22 is controlled so that the heat contained therein is sufficient to immediately activate the foamable adhesive at the structural sheet-adhesive interface but insufficient to activate the entire body of adhesive. This assures a firm, continuous bond between the sheet adhesive and the structural sheet base without affecting the major portion of the adhesive body. In order to assure minimum activation of the adhesive, the laminate 40 can be passed immediately from the laminating rolls 34 into a cooling chamber 42 where cooling air, supplied by a suitable blower 44, quickly extracts residual heat from the strip 22. Since the strip 22 is quickly cooled after having the foamable adhesive laminated thereon, and since such adhesives are conventionally relatively poor heat conductors, the heat from the strip is prevented from activating the adhesive substantially beyond the interface of the adhesive and the structural strip. Thus, for all practical purposes, the foamable adhesive remains unactivated, though firmly bonded to the strip 22.
The laminate 40 can be passed directly from the cooling chamber 42 into a metal expanding apparatus 46 where the layer of adhesive 36 and structural strip 22 are simultaneously sheared and expanded as more fully described hereinbelow with reference to FIGS. 5 and 6. From the expanding apparatus 46 the expanded reinforcing sheet, or matrix, 48 may be cut into individual lengths if desired or would into a coil 50 illustrated in FIG. 4. Preferably, a separator sheet 52 of a suitable weight paper or the like, fed from a suitable source such as supply roll 54, is deposited on the top surface of the expanded sheet 48, as by use of roll 56, before the reinforcing sheet is wound into a coil. The purpose of the separator sheet 52 is to minimize the likelihood of tearing or otherwise damaging the foamable adhesive laminate in the coiling and uncoiling process, or during handling coils or sheets or the material.
Referring now to FIGS. 5 and 6, operation of the expanding apparatus 46 is schematically illustrated to show the expansion of the laminated sheet 40. Such expanding apparatus is commercially available and well-known to those skilled in the art and therefore the structure and operation of the apparatus will only be described herein to the extent necessary to fully understand the method of forming the novel expanded reinforcing sheet material of the present invention. Thus, expanding apparatus 46 includes a support bed 58 having a horizontal top surface 60 which intersects a vertical front surface 62 at right angles to define a straight, relatively sharp cutting or shearing edge 64. A holddown plate, or block, 66 may be provided above horizontal surface 60 to intermittently clamp and hold a sheet of material being fed through the apparatus during the cutting and expanding operation.
A cutting and expanding die assembly 68 is mounted above support bed 58 in position to cooperate with the cutting edge 64 and vertical surface 62 to shear and expand sheet material fed through the apparatus. Cutting and expanding die assembly 68 is illustrated as being supported by columns, or posts, 70, 72 which are vertically reciprocated by suitable means, not shown, and moved laterally to stagger the rows of slits, or cuts, formed in the sheet material to be expanded.
The cutting and expanding die assembly 68 includes a shearing plate 74 having a plurality of cutting teeth 76 formed on its bottom edge. The cutting teeth 76 each have a substantially flat, generally rectangular bottom end 78, with the width of end 78 in the direction parallel to the cutting edge 64 generally corresponding to the length of the joints 14, i.e., the distance between successive shear lines in a row. The surfaces 80 of the respective teeth outboard of bottom ends 78 extend upwardly at an angle to intersect the corresponding surfaces on the adjacent teeth to give the bottom edge of shearing plate 74 a saw-toothed appearance.
In operation of the expanding apparatus 46, suitable means (not shown) are provided to advance the sheet material to be expanded, i.e., the laminate 40, in increments equal to the width 18 of the individual strands 12, with the incremental feeding of the sheet being synchronized with movement of the cutting and expanding die. Also, clamping plate 66 is raised and lowered, by conventional means not shown, in synchronization with the feeding of the sheet to firmly clamp and hold the sheet during the shearing and expanding step, and to release the sheet for feeding.
When the laminated sheet 40 is advanced to overhang the shearing edge 64 by a distance equal to the width of a strand, shearing plate 74 is lowered so that the bottom end 78 of each tooth 76 initially engage the top, adhesive coated surface of the laminate, and then proceed downwardly to simultaneously shear the laminated adhesive 36 and structural strip 22 along spaced shear lines 82. As the laminated sheet 40 is sheared, the flat rectangular end 78 of teeth 76 press the sheared segments downwardly along the vertical face 62, thereby elongating the strands 12. This expands the sheet 40 by forming openings in the shape of isosceles trapezuids when viewed from the front of the apparatus. During this shearing and expanding step, the adhesive material covering the sheared segments is clamped between the structural strip 22 and the surfaces 78, 80 of the teeth 76.
Upon completion of the shearing operation, plate 74 is raised and shifted laterally so that the flat bottom end 78 is positioned directly above the unsheared section between adjacent, previously formed shear lines 82. At the same time, clamping plate 66 is released and sheet 44 is indexed through the apparatus a distance equal to the width of one strand. The sheet is then clamped and the operation repeated, forming another row of shear lines 82 in offset relation to the initially formed line and converting openings formed in the previous stroke to a generally diamond-shaped configuration. As shown in FIG. 5, as this shearing and expanding operation is repeated, the expanded sheet 48 is guided downwardly around a guide roll 84 then fed to a suitable coiling or winding apparatus as illustrated in FIG. 4.
As shown in FIGS. 2 and 3, it has been found that, by using a relatively resilient rubber based adhesive material laminated onto a relatively high-strength structural strip base, the adhesive can be drawn or caused to roll around the sheared edge of the base strip on one side of the strands and joints. This drawing, or forming of the resilient adhesive results from tensile stresses produced during the expanding or elongating of the strands, and is most evident at the unsupported joint portion between shear lines 82. Thus, as one joint portion is engaged and pressed downwardly by the flat bottom end 78 of a shearing tooth 76, tensile stresses are set up in the top adhesive laminate, causing the adhesive material to be drawn outwardly and over the unsupported edge of the unsheared portion as the shearing plate progresses downwardly in its shearing and expanding movement. As a result, maximum flow of the adhesive over the edge occurs at the joints and reduces gradually along the length of the strand as most clearly seen in FIG. 3.
The resilient adhesive always tends to be drawn around the same side edge of the joints and strands. This materially assists in positively forming a high-strength bond between the reinforcing sheet and a surface of another article since, by placing this edge toward the surface, the adhesive will extend between the joints and the surface. Also, in this position, the face surface of the joints and strands having the adhesive thereon forms an acute angle with the surface to be reinforced. This results in a tendency for the adhesive, when activated, to expand in the direction of such surface. This tendency is increased by any residual stresses in the adhesive as a result of its having been drawn around the sheared edges, with the result that a complete bond is formed between the expanded reinforcing sheet and the continuous surface positioned in contact therewith as illustrated in FIGS. 7-9.
FIG. 7 illustrates, on an enlarged scale, a reinforced structural panel 86 comprising a section of an expanded reinforcing sheet of the type described above bonded to one surface of a thin plate or sheet 88 such as a metal sheet employed as a door panel or hood of an automobile. This perspective view shows the side faces of the strands 12 and joints 14 of the expanded structural sheet which do not have the layer of adhesive bonded thereto, and illustrates the manner in which the foamable adhesive, when activated, increases its volume and forms a bond between the full length of the joints and strands and the smooth surface of sheet 88. This feature is further illustrated in FIGS. 8 and 9. Thus, in FIG. 8, a joint 14 of the rigid strip 22 is shown to be firmly bonded to the flat surface of metal sheet 88 by the adhesive material 20 which as been activated or foamed to enlarge its volume. It is seen that a portion 90 of the foamed adhesive material extends beneath the sheared edge 92. This portion 90 of the adhesive material was drawn from the face of the joint around the sheared edge 92 during the expanding operation in forming the reinforcing sheet. It is also seen that the adhesive extends upwardly from the surface of sheet 88 along the face of the joint which makes an acute angle with the plane of the sheet.
FIG. 9 is a sectional view of a portion of the assembly shown in FIG. 7 taken through one of the strands 12 of expanded reinforcing sheet at a point spaced a substantial distance from the joints. Contact between the sheared edges 92 of the joints and the flat surface of sheet 88 spaces the strands from the surface of sheet 88 due to the angle of the strands as illustrated in FIG. 3. The substantial volume increase of the foamable adhesive material and the position of the strands with the adhesive coated face making an acute angle with the surface of sheet 88 results in the volume growth of the adhesive being directed toward the sheet to form a bond along the full length of the strands. This tendency of the adhesive's volume growth to be directed toward the sheet 88 is increased by the adhesive being drawn at least paritally around the sheared edges facing the surface of sheet 88.
An important contribution of the present invention resides in the selection of a foamable expanding adhesive which can be firmly adhered to the flat surface of the base structural sheet before the laminated structure is expanded, with the bond being able to withstand the substantial stresses inherent in the expanding operation. Also, the adhesive material should have substantial shelf-life after being bonded to the base sheet, and the expanded composite reinforcing sheet should be capable of being handled and shaped or formed without substantial disruption to the bond between the adhesive material and the expanded structural strand before the adhesive is activated.
One commercially available adhesive product which has been found to be particularly well adapted for use in the present invention is adhesive number L-1025 marketed by L & L Products, Inc. of Romeo, Michigan. This is heat-activated foamable rubber based adhesive which has a volume expansion of 80% to 150%, or more, depending upon the intensity of and time of exposure to the activating heat. The activating temperature and exposure time is within the range frequently employed in paint bake cycles, for example temperatures within the range of 250° F. to 375° F. for times of 10 to 30 minutes. The adhesive has a strength of 20 to 50 lbs/in 2 and provides a good bond with both plastics and metals, including oily steel. It is available commercially in relatively thin preformed sheets or coiled strips which are self-supporting and which can be handled in a manner similar to sheet rubber. The adhesive in coiled strip form can readily be laminated onto the surface of a base material such as strip metal with automatic apparatus of the type described hereinablve. After foaming, this adhesive remains flexible over a wide range of temperatures, and provides excellent vibration dampening and sound insulating qualities when the reinforcing sheet according to the present invention is bonded to a thin structural sheet.
Referring now to FIGS. 10-19, an alternate embodiment of the expanded reinforcing sheet according to the present invention, and a method of producing such expanded reinforcing sheet are illustrated wherein a single sheet 100 of foamable adhesive material is supplied from a coil 102 and fed between two continuous strips 104, 106 of formable structural material, supplied from coils 108, 110, respectively. A first heater hood 112 having a heater 114 supported therein is positioned adjacent strip 104 and a second hood 116 having a heater 118 supported therein is mounted adjacent the strip 106. Heaters 114, 118 are controlled by heat sensing elements 120, 122, respectively for sensing the temperature of the structural strips as they exist from beneath the respective hoods. The heated strips 104, 106 are then guided around a pair of driven, silicon rubber covered pinch rolls 124, 126 which press the heated strips into firm engagement with the rubber based adhesive sheet 110, one on each side thereof. The structural strip-adhesive laminate sheet 128 passes from the nip of rolls 124, 126 into a cooling tunnel 130 where cooling air, supplied by a suitable blower 132, quickly cools the heated strips to terminate the heat activation of the adhesive. From the cooling hood 130, the laminate 128 may be coiled or cut into sheets for storage before subsequent expansion or alternatively the running length of laminate can be passed directly through an expanding apparatus 46 as described above, with the expanded reinforcing sheet 134 being wound into a coil as shown at 136 or cut into sheets for subsequent handling and use or storage.
The expanded composite reinforcing sheet shown in FIGS. 12-19 may be considered to consist of two separate expanded structural sheets of the type illustrated in FIG. 1 disposed in parallel, overlying, interfitting relation and joined by the single sheet of adhesive material, and accordingly, a further detailed description of this composite structure is not believed necessary. Components of the structure, including the strands and joints of the respective expanded base sheets are, accordingly, indicated in the various FIGS. by reference numerals corresponding to those employed with respect to the initially described embodiment of the invention.
The expanded reinforcing sheet 134 differs from the expanded reinforcing sheet 48 described above in that the adhesive sheet 100 has both surfaces bonded to a structural sheet and the expanding process does not result in the wrap-around or drawing of the adhesive over the sheared edges. The stresses can result in the top structural strip (e.g. strip 104 in FIG. 10) being shifted slightly with respect to the bottom sheet during the expanding operation as illustrated in FIG. 13. Any such shifting which does occur is not sufficient, however, to materially affect the appearance of the structure.
Although the foamable adhesive sheet does not wrap-around the sheared edges in the sandwich type construction of this alternate embodiment, a good bond can be obtained between the expanded reinforcing sheet and a smooth surface of another article upon activation of the adhesive. Since the adhesive is confined between two relatively rigid structural elements, activation of the adhesive causes it to be extruded from between the adjacent constraining surfaces. This extruding effect results in a substantially equal amount of the foamed adhesive material flowing outward from between the adjacent surfaces of the strands and joints on both sides of the expanded reinforcing sheet as illustrated in FIGS. 15-19.
As with the embodiment of the invention employing only single expanded structural sheet, it is important that the foamable adhesive employed in this embodiment have sufficient strength and dimensional stability to withstand the forces necessary to shear and expand the laminated structure, and to retain the two expanded structural sheets in their interfitting juxtaposed relation after the shearing and expanding operation, to enable the expanded composite assembly to be handled, cut, and shaped as necessary for attachment to a surface of an article to reinforced or stiffened. The rubber based, heat-activated foamable adhesive described above has been found to meet these requirements.
In FIG. 14, a segment of the composite reinforcing sheet material 134 is illustrated as being bonded to the surface of a flat, continuous metal sheet 138. The appearance of this assembly differs somewhat in appearance from that of FIG. 7 in that, in the embodiment of FIG. 14, there is a visible bead 135 of foamed adhesive along the sheared edges of the expanded reinforcing sheet as a result of being extruded in both directions from between the constraining reinforcing sheets. This tendency is more clearly illustrated in FIGS. 15 and 16.
A further features of the embodiment employing a foamable adhesive captured between two expanded structural sheets is demonstrated in FIGS. 17-19 wherein the expanded reinforcing sheet 134 is employed in a sandwich structure 140 to firmly join two continuous structural sheets 142, 144 in spaced relation to one another much in the fashion of the well-known, high-strength honeycomb structural panels. Since the adhesive is extruded outward in both directions, an equal bond may be obtained on either side of the expanded reinforcing sheet material. The panel 140 is very stiff and has a high strength-to-weight ratio. It also has good sound insulation and vibration qualities, which, along with its relatively inexpensive construction, makes it particularly useful as a partition or wall panel.
In a modification of the expanded reinforcing sheet suitable for use for bonding between two spaced surfaces, a single structural sheet may have two layers of adhesive material bonded one to each face surface. When this laminate is expanded, both face surfaces of the strands and joints will be covered with adhesive so that an acute angle will be formed between a surface of an article, e.g., a cover sheet of structural material, and an adhesive covered face of the strands and joints on either side of the expanded reinforcing sheet.
Tests have revealed that structural sheet material reinforced with an expanded composite reinforcing sheet according to the present invention is extremely effective in providing a high stiffness-to-weight ratio while, at the same time, providing effective vibration dampening and sound insulation. This makes the reinforcing material an effective, inexpensive, light-weight reinforcing for various applications including the reinforcing of thin metal panels of the type employed, for example, in building panels, partitions, doors, automobile hoods and door panels, aircraft panels, and numerous applications where weight reduction, high strength and stiffness, or vibration or sound dampening are important objectives. The reinforcing sheet may be readily applied to a surface other than a flat surface, the sheet can be preformed to conform to the surface to be reinforced.
Reference frequently has been made herein to the intermittent type expanding apparatus for simultaneously slitting and expanding sheet material, and the expansion of sheet material on this type of apparatus is believed to be sometimes referred to in the art as a simultaneous expanding operation. The specification also frequently refers to the simultaneous expansion of the structural sheet and the foamable adhesive laminated thereon. It is in this latter since that the term "simultaneously expanding" is used in the claims with reference to the steps of expanding the structural sheet, or sheets, and the layer of foamable adhesive. Also, it is again pointed out that the term "foamable" is employed herein to refer to any type of volume expansion whether or not achieved by a true foaming process.
While preferred embodiments of the invention have been disclosed and described, it should be understood that the invention is so restricted and that it is intended to include all embodiments thereof which would be apparent to one skilled in the art and which come within the spirit and scope of the invention.
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A composite expanded sheet reinforcing material especially useful as a stiffening, vibration and sound dampening, reinforcing laminate, and methods of manufacturing such sheet reinforcing material and of reinforcing articles therewith are disclosed. Formable sheet material having a layer of a foamable adhesive laminated thereon is passed through an expanding apparatus which forms rows of spaced, longitudinally staggered slits through the laminated sheet to form a series of elongated strands integrally joined at their ends by a series of joints or bonds. The slit material is expanded in a direction transverse to the longitudinal direction of the slits, causing the adhesive-coated surfaces of the strands and joints to be inclined at an acute angle to the principal plane of the formed reinforcing sheet. The formed reinforcing sheet may then be laminated onto a surface which is to be reinforced by placing the adhesive-coated surface of the strands and joints in juxtaposed relation to the surface and activating the adhesive.
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BACKGROUND OF THE INVENTION
The invention relates to dual alloy turbine wheels and, more particularly to dual alloy cooled turbine wheels and methods of manufacture thereof.
Various dual alloy turbine wheels are used instead of single alloy turbine wheels in applications in which exceptionally high speed, high temperature operation is needed, since under these circumstances it is necessary to have high creep rupture strength at high temperatures in the blade or outer rim portion of a well designed turbine disk, and it is also necessary under high speed, high temperature conditions to have superior tensile strength and low-cycle-fatigue properties in the hub portion. Superalloy materials which have the former highly desirable characteristics in the blade and outer rim portions of a turbine wheel do not have the high tensile strength and low-cycle-fatigue resistance properties that are required in the hub, and vice-versa. In general, all the desirable qualities for turbine wheel hubs are associated with tough, fine-grained, nickel-base alloys, in contrast to the desired properties of the material of the blade, ring, or rim portions of a turbine disk, in which large-grained, nickel-base alloys with directional structures in the blades are used. The large grained, directional structure alloys possess high creep resistance, but inferior tensile properties.
Where the performance compromises necessitated by use of a single alloy material in a turbine disk are unacceptable, dual alloy turbine wheels have been used for many years, for example, in connection with military engines which utilize AISI Type 4340 alloy steel hubs fusion welded to Timken 16-25-6 warm-worked stainless steel rims, the alloys of which could be fusion-welded to yield joints of adequate strength. More modern, stronger, more complex alloys, however, could not be fusion-welded in typical disk thicknesses without unacceptable cracking. Inertia-welding processes have been used in joining of axial-flow compressor disks into spools and in joining of dissimilar metal shafts to turbine wheels. However, the largest existing inertia welding machines are only capable of welding joints in nickel-based alloys which are a few square inches in cross section, so this process can be used only in the smallest turbine disks.
The bonding of dissimilar metals by hot isostatic pressing (HIP) has been suggested for manufacture of dual alloy turbine wheels, since this process does not have the inherent joint size limitations of the inertia-welding process. Hot isostatic pressing is a process in which the pressure is applied equally in all directions through an inert argon gas in a high temperature pressure vessel or autoclave. Cross Pat. No. 4,096,615, Ewing et al., Pat. No. 4,152,816, and Catlin Pat. No. 3,940,268 are generally indicative of the state of the art for hot isostatic pressing as applied to manufacture of dual alloy turbine wheels. Kirby Pat. No. 3,927,952, assigned to the present assignee, is indicative of the state of the art in manufacture of cooled turbine disks and discloses photochemically etching recesses in thin single alloy disks to produce corresponding holes which are aligned when the disks are subsequently vacuum diffusion bonded together to create a laminated structure in which fluid cooling passages extend from a central bore of the hub to and through the turbine blades. Cooled turbine discs are necessary in small, high-temperature gas turbine components that are subjected to exceedingly high external gas temperatures, wherein the blade metal temperatures may reach the range of 1700 to 1800 degrees Fahrenheit. The cooling passages are necessary to prevent the blades from exceeding this temperature range in order to prevent excessive creep of the blade material.
The above mentioned dual alloy turbine wheels have become attractive because their optimum material properties in both the hub portion area and the ring and blade portion of turbine disks have allowed the minimization or elimination of cooling fluid requirements and have allowed lighter weight turbine disks to be utilized. However, there nevertheless remains a need for an ultra-high performance dual alloy turbine wheel that is capable of operating in conditions that would produce unacceptably high blade temperatures even in the best prior art uncooled dual alloy turbine wheels.
Accordingly, it is object of this invention to provide an ultra-high performance turbine wheel and a practical method of manufacture thereof which has all of the advantages of prior dual alloy turbine wheels and further provides suitable fluid cooling passages to the blades of the disk.
SUMMARY OF THE INVENTION
Briefly described, and in accordance with one embodiment thereof, the invention provides a high performance, cooled, dual alloy turbine wheel and method of manufacture thereof, wherein a hollow cylinder of first superalloy material having high creep rupture strength up to approximately 1800 degrees Fahrenheit is cast against a chill to produce a radial directional grain structure; the hollow cylinder then is filled with second superalloy material having the properties of high tensile and high low-cycle-fatigue strengths, after which deformable plates are bonded to the cylinder to tightly seal the second superalloy material therein and the assemblage then is subjected to hot isostatic pressing to achieve direct metallurgical diffusion bonding of the second superalloy material to the cast cylinder; the resulting dual alloy cylinder then is sliced into a plurality of thin, precisely flat dual alloy wafers or laminae, which are cut to produce cooling holes, and then are reassembled to produce a laminated cylinder from which the cooled dual alloy turbine wheel can be machined. In the described embodiment of the invention, the first superalloy material of which the cast cylinder is formed consists of MAR-M247 alloy and the second superalloy is in the form of a pre-consolidated preform composed of powder metal low carbon Astroloy material. After the hot isostatic pressing, the resulting dual alloy cylinder is machined to produce a precise cylinder. Slicing of the resulting dual alloy cylinder into wafers is accomplished by a process that results in precisely flat wafers. Photochemical etching or laser cutting techniques are used to cut cooling holes in locations at which the turbine blades will be formed later. The wafers are coated with elemental boron or a nickel-boron alloy, aligned so that their respective cooling holes form fluid cooling passages, and are subjected to hot axial pressing to vacuum diffusion bond the wafers together to produce the laminated structure. The laminated structure then is appropriately heat treated and inspected, and machined using conventional techniques to form the turbine blades and other features of the turbine wheel. Extremely high creep strength is achieved in the blade material. Extremely high tensile strength and high low-cycle-fatigue strength are achieved in the hub portion of the turbine wheel. These properties result in an extremely high performance turbine wheel that can withstand very high temperature, high speed operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of a cast hollow cylinder of superalloy material having high creep rupture strength, in accordance with the present invention.
FIG. 2 is a section view of a subsequent step in the manufacture of the present invention illustrating placement of a second alloy preform in the cylinder of FIG. 1 and attachment of sealing end caps to prepare the assemblage for hot isostatic pressing.
FIG. 3 illustrates a section view of the resulting dual alloy cylinder after machining thereof to form a precise cylindrical block.
FIG. 4 illustrates slicing of the dual alloy cylinder of FIG. 3 into thin, precisely flat dual alloy wafers.
FIG. 5 is a plan view illustrating one of the dual alloy wafers of FIG. 4 after photochemical etching thereof to produce fluid cooling holes and illustrating the wrought alloy hub and the cast alloy blade sections thereof.
FIG. 6 is a perspective view of the laminated dual alloy cylinder with cooling passages formed therein.
FIG. 7 is a perspective view illustrating a completed radial flow turbine wheel formed by machining the laminated cylinder of FIG. 6.
FIG. 8A is a section view of one blade of a cooled axial flow turbine wheel made in accordance with the method of the present invention.
FIG. 8B is a section view of one blade of another cooled axial flow turbine wheel made in accordance with the invention.
FIG. 9 is a flow diagram useful in explaining the manufacturing process of the present invention.
DETAILED DESCRIPTION
Referring now to the drawings, reference numeral 1 in FIG. 1 designates a cast hollow cylinder. Cylinder 1 is cast of a material having very high creep rupture strength. A suitable material would be a nickel-based superalloy material, such as MAR-M247 material. Preferably, the procedure of casting cylinder 1 would be to cast it against a chill (i.e., by providing a chilled copper outer mold wall against which the outer portion of the cast, molten alloy metal presses so that the outer portions of the molten metal rapidly freeze, producing radial, directional solidification. The radial lines shown in FIG. 1 on the top of cylinder 1 indicates the resulting radial grain structure. This results in maximum creep rupture strength. Note that this first step (of casting cylinder 1) is designated by reference numeral 35 in the process flow chart of FIG. 9.
The next step in the process is to precisely machine the cylindrical hole 1A in cylinder 1 so that a very close fit can be provided against the surface of a hub preform. The hub preform is designated by reference numeral 2 in FIG. 2. As mentioned above, the hub portion of the turbine wheel being manufactured needs to have maximum low-cycle-fatigue and high tensile strength properties. A suitable preform 2 having these properties can be composed of preconsolidated powder metal low carbon Astroloy, a fine grained superalloy material.
The outer diameter face of preform 2 is machined to achieve a precise fit into the machined cylindrical hole 1A into cast cylinder 1. Subsequent to machining the outer diameter of preform 2, it is inserted into the center of the cast cylinder 1. This step is indicated in block 36 of FIG. 9. Normally, hub preform 2 would be manufactured by hot isostatic pressing techniques to make a cylindrical "log" from which the preforms 2 are machined. After the precise fit has been achieved, the two deformable end plates 3 and 4 are peripherally bonded to cast cylinder 1. The bonding can be achieved by the known technique of electron beam welding, which produces electron beam weld spikes 5 to affix and seal the deformable plates 2 and 4 to the cylinder 1. A secondary seal around the preformed hub 1 and deformable plates 3 and 4 is accomplished by brazing the outer circumference of deformable plates 3 and 4 to produce activated diffusion bonding that provides the additional seals designated by reference numerals 6 and 7. This step is recited in block 37 in the flow chart of FIG. 9. The electron beam welding techniques and peripheral brazing techniques are well known and can be easily provided by those skilled in the art. The deformable plates 3 and 4 can be composed of Inconel 625 sheets, which are typically 0.040-0.080 inches thick.
As indicated in block 38 of the flow chart of FIG. 9, the next step is to hot isostatically press the assemblage of FIG. 2 in order to achieve vacuum diffusion bonding of hub preform to cast cylinder 1. The hot isostatic pressing procedure would typically be performed for four (4) hours at 15,000 psi pressure and 2200° F. temperature. Activated diffusion bonding is described in detail in the November 1970 welding research supplement of the Welding Journal of the American Welding Society at pages 505-S to 509-S by George Hoppin III, and T. F. Berry, also incorporated herein by reference.
As indicated by block 39 in the flow chart of FIG. 9, the next step in the process for making the dual alloy cooled turbine wheel of the present invention is to machine the ends of the block illustrated in FIG. 2 and formed by the hot isostatic pressing procedure in order to remove the deformable end plates 3 and 4 and produce a machined cylindrical "log" designated by reference numeral 10 in FIG. 5 and having a rectilinear cross section. This rectilinear log is then suitable for the subsequent step which, as indicated in block 40 of FIG. 9, is to slice the dual alloy cylinder 10 into a large number of thin, extremely flat dual alloy wafers or laminae, generally designated by reference numeral 10A in FIG. 4. Typically, the thickness of each of the wafers 10A might be in the range from 0.020 to 0.040 inches. Reference numeral 1B in FIG. 4 designates the outer alloy portion of the wafers 10A, which has the desired high creep rupture strength needed in the turbine blades, while reference numeral 2A designates the hub portion having the desired fine grained alloy structure with high low-cycle-fatigue and high tensile strength properties.
The degree of flatness required for the wafers 10A is quite high; a flatness of approximately plus or minus one percent of the wafer thickness is desirable. This is in contrast with aircraft engine industry normal standards for sheet thickness, where the tolerance is ±10%. Various techniques could be used for slicing the dual alloy block 10 of FIG. 3 into the wafers 10A. The presently preferred technique is to use "wire EDM" (electrical discharge machining) devices which are widely used to obtain precise cutting of metals.
As indicated in block 41 of the flow chart of FIG. 9, the next step in the manufacturing process of the present invention is to photochemically machine each of the dual alloy disks 10A to produce the fluid cooling passages that will be needed in the turbine blades of the turbine wheel ultimately produced by the process of the present invention. Reference numerals 11 in FIG. 5 generally designate a particular group of such cooling fluid holes that form a portion of one of such cooling passages which will ultimately extend through one of the subsequently formed turbine blades. Alternately, other machining techniques could be used, such as laser cutting to produce the fluid cooling holes 11. In FIGS. 5 and 6, holes 11 are the air inlets for the respective blades of the turbine wheel being manufactured. Each air inlet hole 11 extends through a path, which may be quite complex, in a separate blade of the turbine wheel.
Next, as indicated by block 42 in FIG. 9, it is necessary to align the corresponding fluid cooling passages 11 in all of the dual alloy disks 10A so that the fluid cooling passages of the turbine wheel are formed. The disks 10A are all laminated together to produce the reconstructed dual alloy block designated by reference numeral 10B in FIG. 6. As mentioned in the above referenced Kirby Pat. No. 3,927,952, (which is owned by the present assignee and is incorporated herein by reference) the laminated rectangular block 10B can be formed of the thin wafers 10A by coating them with a suitable braze or diffusion bonding alloy, which can be applied in various ways, such as by spraying, dusting, or placing a brazed alloy foil between the adjacent wafers. A preferred technique is to deposit elemental boron in carefully controlled amounts by chemical vapor deposition. The coated wafers then are stacked in a predetermined order, with the fluid cooling holes 11 properly aligned, and are subjected to a vacuum diffusion bonding process at a suitable elevated temperature, such as 2200° Fahrenheit under a suitable axial pressing force (10-100 psi).
After appropriately heat treating and inspecting the resulting "log" 10B of FIG. 6, the final step in the manufacturing process of the present invention is to utilize conventional machining techniques to produce a cooled, dual alloy turbine wheel, such as the radial flow turbine wheel, designated by reference numeral 10C in FIG. 7, wherein reference numeral 13 generally designates the blades. Reference numeral 14 generally designates the ends of some of the fluid cooling passages in the blades of the final turbine wheel that are obtained by the above-mentioned photochemical machining of holes 11 in the dual alloy discs 10A and proper alignment thereof during the vacuum diffusion bonding procedure by which laminated cylinder 10B is formed.
Although the above example leads to the construction of the cooled radial flow turbine wheel of FIG. 7, the same techniques can be applied to the manufacture of axial flow turbine wheels. FIGS. 8A and 8B show section views of blades of two such cooled axial flow turbine wheels. In FIG. 8A, reference numeral 2A designates high tensile strength, high low-cycle-fatigue strength material of the hub portion of an axial flow turbine wheel. Reference numeral 1B generally designates the high creep strength blade portion of the turbine wheel. Reference numeral 11 designates the cooling air inlet of the blade, leading to a complex network of air passages 45 formed by properly aligned cooling holes in the various laminated disks. The arrows 46 indicate the general direction of cooling air flow in the passages 45. The cooling air is exhausted from outlets at the tip and the trailing edge of the blade and through "showerhead" holes in the leading edge of the blade (not shown in FIG. 8A). FIG. 8B shows another section view of the blade of a simpler axial flow turbine wheel, wherein the cooling passages extend from the inlet 11 to outlets only at the tip of the blade.
Thus, the invention provides a dual alloy turbine wheel that has optimum materials and cooling circuits for a cooled integral turbine wheel. The method also provides a practical method of manufacture of the turbine wheel. The turbine wheel of the present invention should provide significant advantages for certain small, extremely high speed, high temperature turbine engines.
While the invention has been described with reference to a particular embodiment thereof, those skilled in the art will be able to make various modifications to the described embodiment of the invention without departing from the true spirit and scope thereof. It is intended that elements and steps which are equivalent to those disclosed herein in that they perform substantially the same function in substantially the same way to achieve substantially the same result be encompassed within the invention.
For example, it is not essential that the hub preform 2 be sliced along with the annular cast cylinder 1, since no cooling holes are needed in the hub. Therefore, the annular cast cylinder 1 as shown in FIG. 1 could be sliced to produce wafers or disks in which cooling passage holes are cut, as by photochemical etching. These etched disks can be laminated to reconstruct the annular cylinder 1, and the hub preform 2 then can be inserted into the hole (corresponding to 1A in FIG. 1) of the reconstructed annular cost cylinder and attached thereto by diffusion bonding.
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A dual alloy cooled turbine is manufactured by casting a hollow cylinder of first nickel-base alloy material with high creep resistance to produce directionally oriented grain boundaries. A preform of a second nickel-base alloy material with high tensile strength and high low-cycle-fatigue strength is diffusion bonded into the bore of the hollow cylinder by subjecting the cylinder and preform to hot isostatic pressing. The resulting cylindrical block is cut into thin precisely flat wafers. A plurality of alignable holes for forming fluid cooling passages are photochemically etched into the individual wafers. The wafers then are laminated by vacuum diffusion bonding techniques, with the holes aligned to form fluid cooling passages. The resulting laminated block is machined to produce the turbine wheel with turbine blades through which the cooling passages extend.
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This application claims the benefit of U.S. Provisional Application No. 60/011,304 filed Feb. 7, 1996 and Provisional Number 60/012,787 filed Mar. 4, 1996.
The present invention relates generally to apparel. More particularly, the present invention relates to shirts.
As people get older, their ability to withstand high temperatures declines. Sustained high temperature conditions may even be critical to their very survival. Yet many older people may not have the financial means to remain sufficiently cool under such conditions.
Joggers may find temperatures approaching 100 degrees F. and more to be too high for jogging comfortably. Such temperatures curtail other outdoor sports activities as well.
Art which depicts various devices for warming or cooling includes U.S. Pat. Nos. 2,566,533; 3,717,145; 4,005,494; 4,641,655; 4,688,572; 4,776,042; 4,805,619; 4,805,620; 5,016,629; 5,069,208; 5,133,348; and 5,424,519. However, none of these devices are suitable for providing a generalized cooling effect over the bodies of joggers, older persons, and others during high temperature conditions or for providing a generalized warming effect over the bodies of persons during cold conditions.
It is accordingly an object of the present invention to provide such cooling to older people, joggers, and others in high temperature conditions.
It is another object of the present invention to provide such a generalized warming effect.
It is a further object of the present invention to provide such a cooling and/or heating effect conveniently.
In order to provide such cooling, in accordance with the present invention, one or more pouches are provided in combination with the shirt, and a cooling pack is provided in each pouch. Each cooling pack comprises one or more sealed compartments containing a material which changes state thereby absorbing heat when the cooling pack is exposed to a predetermined temperature. In order to provide such warming, sealed warming packs are receivable in the pouches. For convenience of the wearer, pouches may be provided on the inner surfaces of the shirt so that the shirt may present an aesthetically-pleasing appearance, and the shirt with the cooling and/or heating packs in the pouches placed in a freezer and/or microwave oven respectively for charging the packs.
The above and other objects, features, and advantages of the present invention will be apparent in the following detailed description of the preferred embodiments thereof when read in conjunction with the accompanying drawings wherein the same reference numerals denote the same or similar parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a shirt which embodies the present invention.
FIGS. 2 and 3 are sectional views thereof taken along lines 2--2 and 3--3 respectively of FIG. 1.
FIG. 4 is a rear view thereof.
FIG. 5 is a view of a portion of a shirt in accordance with an alternative embodiment of the present invention.
FIG. 6 is a sectional view of the shirt portion of FIG. 5 taken along lines 6--6 thereof.
FIG. 7 is a schematic view of a vest, in an unbuttoned condition, in accordance with another alternative embodiment of the present invention.
FIG. 8 is a sectional view taken along lines 8--8 of FIG. 7.
FIG. 9 is a schematic view of a freezer compartment in which the vest of FIG. 7 is placed for freezing the liquid in cooling packs thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 to 4, there is shown generally at 10 a shirt, which may be a T-shirt worn by a jogger on a summer day or any other suitable shirt such as one that buttons down the front. The shirt 10 includes a neck opening 12, a lower opening 14 which generally circumscribes the wearer's waist, and a pair of short sleeves 16 containing arm openings 18. The shirt 10 may alternatively have long sleeves or no sleeves at all. The shirt 10 may be composed of a woven cotton or other suitable natural or synthetic material and may be plain or have designs thereon. The shirt 10 has a front panel 20 for covering the wearer's chest and a back panel 22 for covering the wearer's back. For the purposes of this specification and claims, a "shirt" is defined as any article of apparel constructed to be worn by a person to substantially cover the person's upper torso. For example, the shirt 10 may be a sleeveless button-down vest.
In order to cool the wearer of the shirt 10 during hot weather conditions, in accordance with the present invention the shirt 10 is provided on its outer surface 28 with at least one pouch 24 in which a cooling pack 26 is removably placed. FIG. 1 shows a single pouch 24 on the lower portion of the front panel 20, and FIG. 4 shows two pouches 24 on the back panel 22, one on the upper portion and one on the lower portion. The pouches 24 may comprise panels of cloth material sewed to the shirt, as illustrated at 42, to extend substantially over the widths of the respective panels 20 and 22, i.e., perhaps about 3/4 of the respective width. For example, for a medium shirt, each pouch may have a length of perhaps about 8 to 10 inches and a height of perhaps about 3 to 5 inches. Since the breast area may be sensitive to women, it may be desired that a pouch not be placed on the upper portion of the front panel 20 especially of a women's shirt, but a pouch may be placed there if desired. The pouches may have other suitable sizes, may be of different sizes, may be of a greater number of smaller size, may extend vertically rather than horizontally, or otherwise suitably sized and positioned to optimize cooling effect over the wearer's torso. However, it is preferred to minimize the number of pouches in order to minimize the number of cooling packs to be used.
The pouches 24 are shown to have openings at both ends thereof. Each opening is closable by a flap 36 having hook and loop-type fasteners such as Velcro fasteners, illustrated at 38 and 40 on the flap 36 and pouch 24 respectively. If desired, a pouch may be provided with only one opening, and the opening may, if desired, be provided at the top edge of the pouch. The openings may be closed by other suitable means, for example, zippers or snaps or buttons.
The cooling pack 26, which is sized to extend over the length and height of the respective pouch to substantially fill the pouch, comprises a plurality of permanently sealed and independent liquid-containing compartments, illustrated at 30, composed from a suitable material such as a synthetic plastic which is relatively thin, flexible, heat-transmissible, and impervious to the liquid. The material is sealed together at spaced intervals both longitudinally and laterally, providing narrow flat seal portions, illustrated at 32, to provide a waffle appearance, as seen in FIG. 1, the seal portions 32 being bendable so as to allow flexibility of the cooling pack. Each of the compartments 30 may be perhaps about 1/2 to 11/4 inch by about 1 to 21/2 inches and have a thickness when the liquid therein is frozen of perhaps about 1/8 to 3/8 inch. The compartments 30 may contain water or other suitable liquid, illustrated at 31, which will absorb heat to change state such as from ice to water under temperatures of 80 to 110 degrees and more at which the shirt may be worn. An example of such a cooling pack is disclosed in connection with bandages and other therapeutical devices in U.S. Pat. No. 2,566,533 to Poux, which patent is hereby incorporated herein by reference. A suitable cooling pack called a Ice Mat pack is contained within a net-like enclosure on an inner wall of a lunch box called the Cool Sack lunch pack sold by Igloo Products Corp. of Houston, Tex. Alternatively, the material 31 may be of a type which changes state from a liquid to a gas at the predetermined temperature range. Suitable cooling packs may, for example, be obtained from Cryopack Corporation of Vancouver, B.C. These packs, which have 6 ml. and 12 ml. compartments, are described in U.S. Pat. No. 4,931,333, which is incorporated herein by reference.
After their insertion in the pouches, the openings at the ends of the pouches should be closed by means of the Velcro fasteners.
When not being used with the shirt, the cooling packs 26 are suitably left in a freezer so as to keep the liquid in the individual compartments 30 frozen, ready instantly for use of the cooling packs. Even when the liquid is frozen, the bendable flat portions 32 allow the cooling packs 26 to remain flexible. In temperatures in the 90's, it is believed the cooling packs 26 may maintain cooling of the wearer's body for more than an hour, long enough for a jogger to remain cool in high temperatures. When a set of cooling packs 26 loses cooling effectiveness, it may be exchanged with another set of cooling packs 26 which has been kept in the freezer while the first set is being used. Of course, the shirt may be worn as an ordinary shirt, i.e., without the cooling packs.
The pouches 24 may be composed of a suitable insulative material such as, for example, polypropylene material. While the material of the shirt 10 will buffer the effects of the cooling packs 26 on the wearer's body, the shirt panels 20 and 22 may be padded with additional material at the locations of the pouches, as desired, in order to optimize comfort as well as cooling effect, using principles commonly known to those of ordinary skill in the art to which this invention pertains. It is believed that the provision of the cooling packs may provide a generalized cooling feeling over the body of the wearer.
FIGS. 5 and 6 illustrate the placement of a pouch 50, similar to pouches 24, on the inner surface 52 of a shirt panel 54 in order to provide an enhanced shirt appearance, in accordance with an alternative embodiment of the present invention.
If desired, in order to provide enhanced flexibility for wearer comfort, each of the compartments 30 may contain a mass of heat-exchanging fluid such as a gel or emulsion having a high specific heat. Each of the compartments may also contain a set of cells in a fluid-tight and flexible covering having a mass of thermally active material which presents a change of state when subjected to the range of temperature for use, such as described in U.S. Pat. No. 5,069,208 to Noppel et al, which is hereby incorporated herein by reference. The fluid mass does not change state to a solid at a temperature at which the thermally active material changes to a solid so that the fluid mass remains a fluid when taken from a freezer to be worn by a user. Alternatively, the cooling pack may comprise a single compartment or perhaps 2 or 3 compartments containing the fluid mass in which is dispersed a plurality of cells of the thermally active material.
In accordance with an alternative embodiment of the present invention, it is envisioned that one or more ice packs may be permanently encased or secured in a zip-out lining. In accordance with another alternative embodiment, it is envisioned that one or more ice packs may be permanently encased or secured in a pouch or pouches of the shirt in which event the entire shirt would be placed in a freezer. In this event, the shirt would be worn over an undershirt. For the purposes of this specification and the claims, the term "pouch means" is meant to include a zip-out lining or any other suitable structure for containing one or more of the ice packs.
For use of the shirt for body warming purposes in the winter, suitable warming packs may be substituted for the ice packs. For example, U.S. Pat. No. 5,424,519 to Salee, which is hereby incorporated herein by reference, discloses a seat cushion in which is embedded a thermal storage unit. A microwave-activated thermal storage material is sealingly contained within a cover of the thermal storage unit. Such a thermal storage unit or any other suitable sealed warming pack may be suitably substituted for an ice pack in each pouch of the shirt for warming the body during cold temperatures. Alternatively, the shirt may be provided for receiving only such warming packs.
Suitable wrist bands in which are removably or permanently received sealed ice packs, as described above, may be worn, such as by joggers, to provide a feeling of coolness.
Referring to FIGS. 7 and 8, there is illustrated generally at 60 a shirt in the form of a vest in accordance with an alternative embodiment of the present invention. The vest 60 has a back panel 62 and two half front panels 64 joined to the back panel 62 by seams 66 respectively. A pair of arm holes are illustrated at 68. An upper edge for providing an opening for the neck is illustrated at 70. The front panels 64 are joined at their terminal edges by a plurality of buttons 72 on one terminal edge which engage buttonholes 74 on the other terminal edge. The front panels 64 may be joined by other suitable means such as, for example, a zipper. The shirt 60 is thus of a type which opens down the front. The shirt 60 has an inner surface 76 for engaging the wearer's body or undershirt and an outer surface 78.
A plurality of strips 80 of webbed or other suitable material are sewed to the inner surface 76 as illustrated by stitching 82 which extends entirely around the perimeter of each strip 80 to form with the inner surface 76 a closed pouch. The material of which strips 80 is composed is desirably washable. The pouches 80 may be provided on the inner surface 76 so as not to detract from the outer surface appearance so that the shirt may have an aesthetically-pleasing appearance. A cooling pack 84, which may be similar to one of the compartments 30 of a cooling pack 26, is contained within each of the pouches 80.
By webbed material is meant a cloth-like material such as, for example, 12-count needlepoint Aida cloth material, having a plurality of spaced strands, illustrated at 86, extending in one direction and a plurality of spaced strands, illustrated at 88, extending in a direction cross-wise thereto, leaving spaces or voids, illustrated at 90, therebetween for easy transmissibility of the cooling effect of the cooling packs 84. Yet the pouch material offers some insulation from direct contact with the cooling packs 84 to enhance comfort of the wearer. It should, however, be understood that the pouches 80 may be composed of other suitable material which offers suitable transmissibility of the cooling effect.
FIG. 9 illustrates a bag 92 in which the vest 60 may be placed, the bag 92 having a closable opening 94. For example, the bag 92 may be a zip-lock bag, or the bag 92 may be a plastic bag closed by a twist tie. The bag 92 with the vest 60 contained therein is placed in the freezer compartment 96 of a refrigerator for freezing the liquid in the freezer packs 84 prior to wearing of the vest 60. The bag 92 is provided to segregate the vest 60 from food products. One or more vests 60 may be kept in the freezer 96 while another is being worn. When one has lost its effectiveness, after perhaps an hour of wear, it may then be exchanged with one from the freezer 96 having frozen cooling packs 84.
The vest 60 may be worn over a shirt to enhance comfort or without an undershirt to maximize the cooling effect. The elimination of the necessity to remove and replace cooling packs affords convenience to the wearer.
Instead of cooling packs 84, the pouches 80 may be provided to contain warming packs such as disclosed in the aforesaid Salee patent. This would of course require that the shirt 60 be subjected to microwave energy in a microwave oven to charge the warming packs. Accordingly, the materials of which the shirt 60 and pouches 80 are composed are suitably of types which are microwave transparent and fire retardant, such as materials (for example, nylon) described in the Salee patent for suitably passing and withstanding microwave energy.
Alternatively, the strips 80 may be stitched to the shirt 60 only along three sides and have a closable opening along the upper side so that cooling packs and warming packs may be interchanged in the pouches for summer-wear and winter-wear, respectively. This also allows the shirt 60 to be more easily laundered since the cooling or warming packs may be first removed.
In accordance with an alternative embodiment of the present invention, a single piece of material may be sewed to the inner surface 76 of the vest 60 to provide a plurality or all of the pouches.
Although the invention has been described in detail herein, it should be understood that the invention can be embodied otherwise without department from the principles thereof, and such other embodiments are meant to come within the scope of the present invention as defined in the appended claims.
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In combination with a shirt, one or more pouches which receives a cooling and/or warming pack. The cooling pack comprises sealed compartments containing water or other material which changes state thereby absorbing heat to cool the wearer when the cooling pack is exposed to a predetermined temperature for wearing of the shirt. The warming pack sealingly contains a material which is heatable to store heat and to release the stored heat when the warming pack is exposed to a predetermined temperature for wearing of the shirt. The cooling pack may also be provided as part of a wrist band.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is cross-referenced to and claims priority from U.S. Provisional application No. 60/253,315 filed Nov. 17, 2000, which is hereby incorporated by reference.
U.S. GOVERNMENT RIGHTS
[0002] This invention was made with U.S. Government support under contract No. ECS-9522195 awarded by the National Science Foundation. The U.S. Government has certain rights in this invention.
FIELD OF THE INVENTION
[0003] This invention relates generally to an apparatus and method for DNA sequencing. More particularly, it relates to an apparatus and method for DNA sequencing based on the direct observation of polymerase with a nanometer scale electrometer.
BACKGROUND
[0004] DNA sequencing is a major challenge. For instance, the process of determining the exact order of the 3 billion chemical building blocks making up the DNA of the 24 different human chromosomes has been and still is the greatest technical challenge in science and technology. The resulting DNA sequence maps will help reveal the estimated 100,000 human genes within our DNA as well as the regions controlling them that can then be used by 21 st century scientists to explore human biology and other complex phenomena.
[0005] Transcription is the process by which the nucleotide sequence of DNA is replicated into RNA. Transcription starts with unwinding DNA at the beginning of a gene. Then nascent RNA is synthesized by a complementary base pairing with the template strand of DNA. The synthesis site moves along template DNA. Further reference for the transcription process can be found in a book by Paul Berg and Maxine Singer, entitled “ Dealing with Genes”, published by University Science Books, Mill Valley, 1990. This process is accomplished with a class of proteins called RNA polymerases. These proteins directly replicate the sequence of a template strand of DNA by constructing a nascent RNA strand from individual nucleotides. Transcription occurs when the RNA polymerase binds to a discrete DNA sequence that defines the beginning of a given gene. The discrete sequence, known as a promoter region, signals the RNA polymerase to separate the two strands of the DNA and begin replicating one of the strands into a strand of nascent DNA. Each nucleotide that is added to the nascent RNA is determined by complementary base pairing with successive nucleotides of the template DNA. For example, an A, G, T, or C in the DNA template strand correspond to a U,C, A or G in the nascent RNA strand. The polymerase moves along the template DNA while it continues to add nucleotides to the nascent RNA until the end of the gene is reached. At this point, the transcription is terminated and the completed strand of RNA is released.
[0006] The movement of RNA polymerase relative to the template DNA has been previously observed both by force detection and optical methods. Schafer et al. (1991) in a paper entitled “ Transcription of single molecules of RNA polymerase observed by light microscopy”, published in Nature 352, page 444, observed transcription by a single RNA polymerase molecule using light microscopy to detect the Brownian motion of a gold particle that was attached to the template. Analysis of the Brownian motion enabled Schafer et al. to measure the movement of the template DNA relative to the polymerase molecule. Yin et al. (1995) in a paper entitled “Transcription against an applied force”, published in Science 270, page 1653, demonstrated that the force produced by a single RNA polymerase could be measured with an optical trap. At the start of the transcription, the RNA polymerase is immobilized on a glass slide. One end of the template DNA is attached to a polystyrene bead in the optical trap while the other end is bound to the polymerase. During transcription, force exerted by the polymerase on the bead was monitored as a function of time by measuring the bead position with an interferometer. While both of these experiments give direct evidence that the RNA is indeed replicating, they do not detect specific nucleotide sequence.
[0007] U.S. Pat. No. 6,280,939 to Veeco Instruments, Inc. teaches a method and apparatus for DNA sequencing using a local sensitive force detector DNA sequencing that is performed in real time using an atomic force microscope (AFM). The AFM's probe detects motions that occur when a polymerase incorporates nucleotides into a growing polynucleotide chain and a newly formed double-stranded polynucleotide helix translocates (or “ratchets”) through the polymerase's reaction site. These motions generate a mechanical force that is reflected, either directly or indirectly, by motion of the AFM cantilever. The resulting changes in cantilever motion are detected and can be recorded as an indication that a nucleotide has been incorporated into the DNA template. To determine which nucleotide type has been incorporated, a characteristic of the incorporation of at least one nucleotide type of interest is flagged so as to be distinguishable from the corresponding characteristics of the incorporation of nucleotides of other types.
[0008] U.S. Pat. No. 6,238,871 to Sequenom, Inc. teaches a method to sequence DNA by mass spectrometry. The improvements of this method over the existing DNA sequencing technologies are high speed, high throughput, no electrophoresis and gel reading artifacts due to the complete absence of an electrophoretic step, and no costly reagents involving various substitutions with stable isotopes. U.S. Pat. No. 6,238,871 utilizes the Sanger sequencing strategy and assembles the sequence information by analysis of the nested fragments obtained by base-specific chain termination via their different molecular masses using mass spectrometry, as for example, MALDI or ES mass spectrometry. A further increase as U.S. Pat. No. 6,238,871 teaches is the throughput that can be obtained by introducing mass-modifications in the oligonucleotide primer, chain-terminating nucleoside triphosphates and/or in the chain-elongating nucleoside triphosphates, as well as using integrated tag sequences which allow multiplexing by hybridization of tag specific probes with mass differentiated molecular weights.
[0009] Accordingly, the demand and importance of DNA sequencing continuously requires the emergence of new methods and techniques that allow for increased DNA sequencing speed and reliability.
SUMMARY OF THE INVENTION
[0010] The present invention provides an apparatus and method for nucleotide or DNA sequencing by monitoring the molecular charge configuration as the DNA moves through a protein, for instance a RNA polymerase, that is capable of transcribing the DNA. The apparatus and method provides a nanoscale electrometer that immobilizes the protein. The protein receives the DNA and transcribes the DNA. The nanoscale electrometer is a sensitive device that is capable of sensing and measuring the electronic charge that is released during the transcription process. The apparatus and method of the present invention further provides monitoring means that are attached to the nanoscale electrometer to monitor the electronic charge configuration as the DNA moves through the protein. Once the electronic charge configuration is established, a correlation is computed, using computing means, between the electronic charge configuration and a nucleotide signature of the DNA. The present invention provides two exemplary embodiments for nanoscale electrometers; first a single electron transistor and second a nanoparticle device. In case of the single electron transistor, the protein is immobilized on the gate of the single electron transistor to receive the DNA. In case of the nanoparticle device, which includes two electrodes and a nanoparticle positioned in between the two electrodes, the protein is immobilized on the nanoparticle to receive the DNA.
[0011] The method of the present invention for sequencing DNA provides the steps of immobilizing a protein that is capable of transcribing DNA on a nanoscale electrometer and delivering the DNA to the protein. The method further provides the step of monitoring an electronic charge configuration at the nanoscale electrometer as the DNA moves through the protein. The method also includes the step of computing, using computing means, a correlation between the electronic charge and a nucleotide signature of the DNA.
[0012] The present invention further provides an integrated circuit chip for sequencing one or more DNA samples. The integrated circuit chip includes a plurality of interconnected nanoscale electrometers and a plurality of proteins that are capable of transcribing one or more DNA samples. The proteins are immobilized on the interconnected nanoscale electrometers to receive and transcribe one or more DNA samples.
[0013] The present invention further provides a method for sequencing one or more DNA samples with the steps of immobilizing a plurality of proteins that are capable of transcribing DNA samples on a plurality of nanoscale electrometers and delivering the DNA samples to the proteins. The method further provides the step of monitoring electronic charge configurations at the nanoscale electrometers as the DNA moves through the proteins. The method also provides the step of computing one or more correlations between the electronic charge configurations and nucleotide signatures of the DNA.
[0014] In view of that which is stated above, it is the objective of the present invention to provide an apparatus and method for DNA sequencing with a transcription protein and a nanoscale electrometer. The advantage of the present invention over the prior art is that the system enables one to directly measure the DNA sequence as the transcription process unfolds.
BRIEF DESCRIPTION OF THE FIGURES
[0015] The objectives and advantages of the present invention will be understood by reading the following detailed description in conjunction with the drawings, in which:
[0016] [0016]FIG. 1 shows DNA sequencing according to the present invention;
[0017] [0017]FIG. 2 shows an exemplary embodiment of DNA sequencing with a single electron transistor according to the present invention;
[0018] [0018]FIG. 3 shows an exemplary embodiment of DNA sequencing with a nanoparticle device according to the present invention;
[0019] [0019]FIG. 4 shows an exemplary embodiment of an integrated circuit chip for DNA sequencing with a plurality of single electron transistors according to the present invention; and
[0020] [0020]FIG. 5 shows an exemplary embodiment of an integrated circuit chip for DNA sequencing with a plurality of nanoparticle devices according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will readily appreciate that many variations and alterations to the following exemplary details are within the scope of the invention. Accordingly, the following preferred embodiment of the invention is set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
[0022] The present invention provides an apparatus and method 100 as shown in FIG. 1 for nucleotide or DNA sequencing by monitoring the molecular charge configuration as a DNA sample moves through a transcription protein 120 . Transcription protein 120 can be any type of protein or polymerase capable of transcribing DNA. In particular, transcription protein 120 is a RNA polymerase. To sequence a known or an unknown strand of template DNA 140 , transcription protein 120 is first immobilized 130 on a nanometer scale electrometer 110 . The present invention teaches two embodiments of nanometer scale electrometers 110 that are used as sensitive devices for measuring electronic charge that is released during the transcription process. These embodiments are described below. A sample of DNA 140 is delivered to the immobilized transcription protein 130 . The sample of DNA 140 could either be a known or unknown piece of DNA or a part of DNA sequence. During this process of immobilization 130 , the electronic charge configuration of the RNA, together with the shape of the transcription protein, will determine the charge in the vicinity of the nanometer scale electrometer 110 , and this will correspond to the nucleotide that is being replicated 150 . Monitoring 160 the charge of the nanometer scale electrometer 110 as a function of time directly measures the dynamic electric field from these activities. Each nucleotide has a distinct signature, and by correlating these signatures 170 to the time domain output of nanometer scale electrometer 110 , DNA 140 is sequenced.
[0023] Sequencing DNA with a Transcription Protein and a Single Electron Transistor
[0024] [0024]FIG. 2 shows an exemplary embodiment of DNA sequencing apparatus 200 . FIG. 2 further shows an exemplary embodiment of nanometer scale electrometer 110 that is used as one of the most sensitive devices and methods for measuring electronic charge. The device in this particular embodiment is called a single electron transistor 110 A. A reference to single electron transistor is, for instance, K. K. Likharev (1999), in a paper entitled “ Single - electron devices and their applications,” published in Proc. of the IEEE Vol. 87(4), page 606. The charge sensitivity of the single electron transistor is far superior to other prior art devices. It is four orders of magnitude more sensitive than electrometers based on the conventional field-effect transistor. For example, a single electron transistor has the capability of modulating a current flow of about 10 9 electrons per second by the presence of half an electron charge on the gate. However, the single electron transistor and field-effect transistor are similar in that they both control the current flowing between the source and drain by the electric field produced by an applied gate voltage. A single electron transistor contains a metal island 210 that is isolated from source 220 and drain 230 electrodes by thin tunnel junctions 240 . There are two effects that control the operation of a single electron transistor. First, the tunnel junctions 240 break the continuity of the classical electron flow into discrete electron units. Second, the Coulomb energy of metal island 210 regulates the number of electrodes that can tunnel in and out of metal island 210 . Altering voltage 250 modifies the Coulomb energy, which controls the source-drain current. The single electron transistor will operate at room temperature if the length scale of tunnel junctions 240 is near 10 μm. The tunnel junctions of the single electron transistor of the present invention preferably ranges from range of 0.1 to 10 nm. The metal island of the single electron transistor of the present invention preferably ranges from 2 to 20 nm.
[0025] Yoo et al. (1997) in a paper entitled “ Scanning single electron transistor microscopy: imaging individual charges”, published in Science 276, page 579 demonstrated that a single electron transistor fabricated on the apex of a tapered fiber could be scanned across a surface and image individual electron charges. Schoelkopf et al. (1998) in a paper entitled “ The radio - frequency single electron transistor: a fast and ultrasensitive electrometer”, published in Science 280, page 1238 presented a radio frequency single electron transistor that achieves a charge sensitivity of 10 −5 electrons per root hertz. Schoelkopf et al. (1998) predict that an optimized version of the radio frequency single electron transistor will be an order of magnitude more sensitive.
[0026] Transcription protein 280 is first immobilized on gate 270 of single electron transistor 110 A. In a preferred embodiment, gate 270 is either constructed or coated with gold. The process of immobilizing a polymerase to a gold surface is well know to a person of ordinary skill in the art. For instance, Schafer et al. (1991, same reference as above) and Yin et al. (1995, same reference as above) have shown that RNA polymerase can be attached to a gold surface using a self assembling monolayer of ω-functionalized alkanethiols 285 . To sequence, transcription protein 280 is immobilized on gate 270 and an unknown strand of DNA 260 is delivered to the transcription protein 280 . During this process, the electronic charge configuration of the RNA and DNA together with the shape of the transcription protein will determine the electronic charge in the vicinity of single electron transistor 110 A. The electronic charge configuration corresponds to the nucleotide that is being replicated. Monitoring, with monitor 290 and leads 290 A, 290 B, the electronic charge configuration, or in other words, the source-drain conductance of single electron transistor 110 A as a function of time directly measures the dynamic electric field from the activities. DNA transcription occurs at a rate of 10-100 nucleotides per second. Typically a single electron transistor has a charge sensitivity on the order of a hundredth of an electron with a 100 ms response time. Monitor 290 could be any type of monitoring device capable of detecting and monitoring the changes in nucleotides with the appropriate sensitivity. Monitor 290 is either an analog or an digital device. Monitoring device 290 could also include computing means in terms of software programs that run on a computer device to monitor, process and calculate any type of parameters from the obtained source-drain conductance. Each nucleotide has a distinct signature, and by correlating these signatures to the time domain output of the single electron transistor, the DNA is sequenced.
[0027] Sequencing DNA with a transcription protein and a nanoparticle FIG. 3 shows exemplary embodiment of DNA sequencing apparatus 300 according to the present invention. FIG. 3 shows another exemplary embodiment of a nanometer scale electrometer 110 that could also be used in the present invention to measure electronic charge. The device in this particular embodiment is a nanoparticle device 110 B. The difference between nanoparticle device 110 B and single electron transistor 110 A is that in case of nanoparticle device 110 B, the charge generated by the transcription process passes through nanoparticle device 110 B and is detected monitor 290 . In case of single electron transistor 110 A a voltage needs to be applied to generate Coulomb energy which controls the source-drain current. Single electron transistor 110 A is then able to sense the charge generated by the transcription process. Nanoparticle device 110 B includes a nanoparticle 310 that is positioned in between two electrodes 320 A and 320 B. The immobilization of transcription protein 330 to nanoparticle 310 is done in a similar way as mentioned above in relation to FIG. 2. Nanoparticle 310 is preferably a gold nanoparticle and is less than 2 nm in diameter to work at room temperature. In order for nanoparticle 310 to directly observe the electronic charges, a sensitivity on the order of a hundredth of an electron with a 100 ms is preferred.
[0028] Integrated Circuit Chips
[0029] The DNA sequencing devices shown in FIGS. 2 and 3 could be constructed on an integrated circuit chip as shown by schematic circuit chips 400 and 500 shown in FIG. 4 and FIG. 5 respectively. Integrated circuit chips commonly span a square centimeter and a plurality of DNA sequencing devices of the present invention could be constructed on the chip. A single DNA sequencing device as shown in FIG. 2 typically occupies a surface of 10 mm 2 . With integrated circuit chips commonly spanning a square centimeter, it is feasible that a million DNA sequencing devices as shown in FIG. 2 could be constructed in parallel. If a million DNA sequencing devices in parallel sequenced at a rate of 100 nucleotides per second, the entire human genome of 3 billion base pairs could be sequenced in less than a minute.
[0030] The present invention has now been described in accordance with several exemplary embodiments, which are intended to be illustrative in all aspects, rather than restrictive. Thus, the present invention is capable of many variations in detailed implementation, which may be derived from the description contained herein by a person of ordinary skill in the art. For instance, various types of nanometer scale electrometers could be employed to measure the electronic charges generated by the transcription process. Various different types of monitoring devices and means as well as different computing devices and methods could be used. All such variations are considered to be within the scope and spirit of the present invention as defined by the following claims and their legal equivalents.
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The present invention provides an apparatus and method for nucleotide or DNA sequencing by monitoring the molecular charge configuration as the DNA moves through a protein that is capable of transcribing the DNA. The apparatus and method provides a nanoscale electrometer that immobilizes the protein. The protein receives the DNA and transcribes the DNA. The nanoscale electrometer is a sensitive device that is capable of sensing and measuring the electronic charge that is released during the transcription process. The apparatus and method of the present invention further provides monitoring means that are attached to the nanoscale electrometer to monitor the electronic charge configuration as the DNA moves through the protein. Once the electronic charge configuration is established, a correlation is computed, using computing means, between the electronic charge configuration and a nucleotide signature of the DNA.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to an external haptic generator for creating haptic feedback in portable electronic devices and more particularly, to external haptic generators in vehicles capable of providing a secure mount for the portable electronic device and creating haptic feedback in portable electronic devices that do not include haptic feedback generators.
2. Discussion
Electronic devices are used throughout our daily lives for many things including communication, entertainment and time management. These electronic devices are increasingly becoming more portable and more powerful thereby allowing users to do an increasingly amount of activities remotely in the course of daily life. For example, many people have smart phones that allow them to access email, surf the web, and do other activities in addition to phone services. Other electronic devices commonly include traditional cell phones, music players, video players, tablets, and GPS navigation devices. More and more users are integrating these devices into motor vehicles.
While a vehicle is in motion, typically a lack of locations exist to securely mount the electronic device. Furthermore, such devices are powered by batteries and require the user to continually monitor battery life and recharge the batteries when needed. As electronic devices become increasingly complex, greater demands are placed on the batteries of the devices thereby shortening battery life. Therefore, many users desire locations in the vehicle that securely mount the electronic devices while they are also being charged and also allow access to the devices by vehicle occupants. For example, many users attach a cell phone to a charger cord plugged into a power outlet in the vehicle and then to prevent the cell phone from falling on the floor or underneath a seat, places the cell phone loosely in a free cup holder. Such placement within a cup holder is not desirable as the cell phone is typically not visible or useable by the occupant unless it is removed which may distract the operator of the vehicle. In vehicles where the cup holders are already in use, these electronic devices many times are free to slide off from a center console onto the floor or under the seat and a driver may become distracted while trying to retrieve the device or monitoring another vehicle occupant retrieving the device.
To improve and enhance the ability for users to interface with various electronic devices, some manufacturers have added haptic feedback device systems to the portable electronic device, however, most portable electronic devices still do not come with haptic feedback devices. In general, haptic feedback systems interface with a user via the sense of touch by applying forces, vibration, and/or other motions to a surface which is then felt by the user. Haptic feedback systems are helpful in providing the user with feedback without visual confirmation by the user especially when the input member is small to easily see, such as a touch screen on a mobile phone. Haptic feedback is very useful in situations where the ability of the user to visually confirm actions may be constrained, such as the operator of a vehicle attempting to provide input to or change settings on any of the portable electronic devices described above.
Most portable electronic devices do not include a haptic feedback generator, however, in view of the above, there is a desire to provide a system which allows for haptic feedback in certain circumstances even if the portable electronic device does not include its own internal haptic generator. In addition, there is a desire to provide a system that securely mounts and places the portable electronic device as well has the capability in certain circumstances to provide a charge to the portable electronic device.
SUMMARY OF THE INVENTION
The present invention relates to an external haptic generator for creating haptic feedback in portable electronic devices and more particularly, to external haptic generators in vehicles capable of providing a secure mount for the portable electronic device and creating haptic feedback in portable electronic devices that do not include haptic feedback generators.
The haptic system for provides haptic feedback in portable electronic devices that do not include integral haptic feedback devices and includes generally a holder configured to hold the portable electronic device; and a haptic generator located within the holder and in communication with the portable electronic device, the haptic generator capable of providing haptic feedback to the holder which is then transmitted to the portable electronic device coupled thereto. The holder is located on one of an instrument panel or center counsel of a vehicle and includes a connector capable of being in electrical communication with the portable electronic device. The holder may further include a wireless communication device capable of wireless interfacing with the portable electronic device and wherein the wireless communication device is in electrical communication with the haptic generator.
Some exemplary holders may include a base housing and a top housing, the base housing having a circumferential outer extent configured to fit within a cup holder in a vehicle and wherein the base housing includes a base and the top housing having a top surface and a front lip and wherein the top surface is angled relative to the outer extent and wherein the top surface is closer to the base proximate to the front lip than the top surface is to the base remote from the front lip and wherein the haptic generator is capable to creating haptic feedback on the top surface.
To provide power to the haptic generator, or even to a connector for charging the portable electronic device, the haptic may further including an inductive power supply.
In addition to separate holders, an instrument panel in a vehicle may be configured with the present invention to be capable of creating haptic feedback in a portable electronic device without haptic feedback capabilities. The instrument panel generally includes a portable electronic device mount capable of extending outwardly from the instrument panel in an open position and being approximately flush with the instrument panel in a second position and wherein the device mount includes a haptic generator in communication with the portable electronic device. The device mount may be one of a cup holder or a drawer and may include an electrical connector capable of interfacing with the portable electronic device. Furthermore, the instrument panel may further including a wireless communication device in electrical communication with the haptic generator and further capable of wirelessly interfacing with portable electronic devices. In some instances, the wireless communication device is a Bluetooth communication device.
The present invention may also be configured into a center counsel for a vehicle capable of creating haptic feedback in a portable electronic device without haptic feedback capabilities, the center counsel generally includes an outer housing defining a cup holder or a drawer, a haptic generator located within the housing and capable of providing haptic feedback to items with the cup holder or drawer. Again, the center counsel may further include a wireless communication device in electrical communication with the haptic generator.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, features and advantages of the invention will become readily apparent after review of the following description of examples of embodiment, with reference to the associated drawings. The drawings show
FIG. 1 illustrates the interior of a vehicle with a tablet being inserted onto an external haptic device;
FIG. 2 illustrates the interior of a vehicle with a tablet showing haptic feedback from a user input;
FIG. 3 is perspective view of an external haptic device configured as a holder on which a portable electronic device is placed;
FIG. 4 is a partial cross-sectional view of an external haptic device configured as the cup holder; and
FIG. 5 is an exploded perspective view of a holder including a haptic generator that will fit in any non-haptic cup holder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is generally illustrated as being placed in a vehicle 10 specifically an automobile, however, any location where it is desirable to have haptic feedback from non-haptic portable electronic devices 30 may include the external haptic device 40 of the present invention. As described herein, the external haptic device 40 will be described as being configured within an automobile, however, other vehicles such as boats or planes may be used. The exemplary vehicle in the Figures includes an exemplary instrument panel 20 from the view of the operator of the vehicle. Of course, the instrument panel 20 may vary in size, shape and configuration depending upon desired design specifications and the location of the haptic devices mounted in the instrument panels and the illustrated recessed drawer 24 or cup holders 26 are only exemplary in location and configuration. In addition, a variety of other support mechanisms may be used to mount the portable electronic device which may include the external haptic device 40 of the present invention to create haptic feedback in the proximate portable electronic device 30 . More specifically, in the motor vehicle, to minimize distraction during operation of the vehicle, the haptic feedback system provides the user with a touch feedback allowing the user to confirm that the desired input was properly entered and received by the vehicle or portable electronic device while allowing the user to stay visually focused where needed during the operation of the vehicle.
FIG. 1 generally illustrates a portable electronic device 30 as a tablet 34 . The tablet 34 would include a device connector (not illustrated) to electronically couple with a connector 46 on the mount 44 in the recessed drawer 24 . In addition to the recessed drawer 24 , other support mechanisms may also be used to properly support the tablet in the desired location and in some embodiments, the tablet 34 may be configured to swivel to face either the driver or passenger of the vehicle.
FIG. 2 is similar to FIG. 1 except that the tablet 34 acting as a portable electronic device 30 has been connected to the connector 46 with the external haptic device 40 providing haptic feedback as illustrated by the vibration lines 41 in FIG. 2 . The type of haptic feedback may be any desired haptic feedback to give the desired input feel. The present invention is configured as illustrated in FIG. 2 to allow a user to press a command on the portable electronic device 30 specifically as illustrated in FIG. 2 to a tablet 34 such that the user may feel that the command that has been entered into the portable electronic device 30 without needing to use visual confirmation. Of course, other portable electronic devices 30 may be substituted for the illustrated tablet 34 such as a phone which will allow haptic dialing of a phone number.
As illustrated in FIG. 3 , the portable electronic device 30 may also be placed upon a separate holder 130 and placed further into a cup holder 26 . Either the holder 130 or cup holder 26 may be configured to include a haptic generator 50 to create the external haptic device 40 . As illustrated in FIGS. 3 and 4 , the cup holder 26 acts as the haptic device 40 . In comparison, the holder 130 in FIG. 5 acts as the external haptic device 40 . Although not illustrated, in some embodiments, it may be possible for an external haptic device 40 to be inserted between the cup holder 26 and holder 130 such that a standard vehicle cup holder and a standard mount may be used while still providing haptic feedback to the portable electronic device 30 . The haptic feedback may be done through direct electric communication such as the connector 46 illustrated in FIG. 1 and in phantom in FIG. 4 . As more specifically illustrated in FIG. 4 , the connector may be at the bottom of the cup holder and the haptic generator 50 may be in direct communication through the connectors to the electronic device 30 . However, in some embodiments, the haptic device 40 and specifically the haptic generator 50 may be in communication with electronic device 30 via a Bluetooth or some other wireless method such that the instructions for the haptic feedback to the haptic generator is provided not through a direct wiring connector as illustrated in FIGS. 1 and 3 but instead through the wireless communication. As further illustrated in FIG. 3 , the cup holder 26 may include a base 28 into which a connector may be situated though the connector and the base of the cup holder is not illustrated in FIG. 3 . The holder 130 is exemplary in size, shape and configuration and is only shown to be configured to securely hold a portable electronic device such as a phone 36 in the desired orientation. The holder 130 is illustrated as having a locating mechanism 144 along with a status indicator 146 . The status indicator may be used to communicate that the phone is charging or that the haptic feedback in either the holder 130 or cup holder 26 is active. The locating mechanism 144 may be configured to fit a variety of portable electronic devices and may vary in size, shape and configuration.
An exemplary sectional view of a cup holder 26 wherein the cup holder 26 forms the external haptic device 40 is illustrated in FIG. 4 . With the cup holder 26 in an open position and a portable electronic device is situated on the base 28 or a holder 130 placed on the base 28 and in turn holding a portable electronic device 30 , haptic feedback may be provided through the cup holder 26 using the haptic generator 50 . The illustrated set up and location of the haptic generator 50 is only exemplary and a wide variety of sizes, shapes, configurations, and locations may be used so long as the portable electronic device 30 receives sufficient haptic feedback.
The present invention will now be described wherein the haptic feedback is provided through an external haptic device 40 acting as a holder 130 for the electronic device 30 and is not specifically originally built into the vehicle or the portable electronic device is not capable by itself of haptic feedback. The external haptic device 40 is generally configured to fit within a cup holder 26 as illustrated in FIGS. 3-5 . The cup holder 26 generally includes sidewalls which retain the holder 130 in position and a base 28 on which the holder may rest. As discussed above, the cup holder 26 may be configured to have a pin connector built into the base 28 . However, such that the cup holder may be used when the holder 130 is not positioned therein, a separate cover (not shown) may be placed over the connector on which a cup would normally rest in the cup holder 26 . However, as illustrated in FIG. 5 , the holder 130 may also receive power through an inductive coil 170 and use that power to drive the electronics 60 and specifically the haptic generator 50 in the holder 130 . Using an inductive coil 170 would allow the holder 130 to take on any size, shape, configuration or be placed anywhere desirable in the vehicle without having to attach special connectors and allow its use in vehicles not originally configured with an external haptic device built into the vehicle.
The holder 130 generally includes a base housing 132 and a top housing 140 . The base housing 132 is configured to fit within the cup holder 26 while the top housing 140 is configured to receive and securely retain for optimal haptic feedback the portable electronic device 30 .
The base housing 132 is generally illustrated in FIG. 5 as having a circumferential outer surface 134 arranged about a longitudinal axis. The circumferential outer surface 134 is generally configured to be cup-shaped and allows the base housing 132 to be inserted similar to most existing cups into standard cup holders 26 and, as such, be securely retained in the cup holder 26 . As illustrated in FIG. 5 at times an extra insert 158 may be used to provide a more secure fit in certain cup holders that are designed for over-sized cups.
The base housing 132 further includes a slanted portion 136 . The angle of the slanted portion 136 may vary depending upon the desired configuration to allow for various locations in the vehicle and allow the user of the external haptic device 40 the best angle to both enter items into the portable electronic device but also to receive the desired haptic feedback.
The top housing 140 generally includes an outer lip 142 for engaging the outer lip 138 of the base housing 132 . The top housing 140 generally includes a locating mechanism 144 having a recessed surface and locating edges 148 . The edges 148 may act as stops to prevent the electronic device 30 from being displaced off the top surface of the top housing 140 . A front lip 143 may also act as an alignment indicator and in some instances may include a status indicator 146 . The haptic driver 50 would engage the top surface 140 and thereby provide haptic feedback to the portable electronic device.
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An external haptic generator for creating haptic feedback in portable electronic devices and more particularly, an external haptic generator in a vehicle providing a secure mount and creating haptic feedback in portable electronic devices that do not include haptic feedback generators.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to display stands of the type used to hold and display merchandise or other items, and more particularly to an illuminated, kiosk type, display stand formed from molded plastic material.
2. Description of the Background Art
A background art search directed to the subject matter of this invention conducted in the United States Patent and Trademark Office disclosed the following United States Letters Patent:
______________________________________2,070,641 2,686,703 3,054,212 3,722,7333,997,220 4,103,782 4,118,082 4,300,248Des. 279,746 Des. 316,637 Des. 325,480 Des. 335,978______________________________________
None of the patents uncovered in the search discloses a kiosk type, illuminated, display stand formed of a pair of hollow, molded plastic, front and rear units that are secured to each other and mounted on a base.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide an illuminated, kiosk type, display stand designed for use in holding and attractively displaying various articles of merchandise and/or other items or materials.
Another object of the invention is the provision of a display stand of the type described that can be easily and economically manufactured.
A more specific object of the invention is to provide a kiosk type, illuminated, display stand formed of a pair of hollow, molded plastic, front and rear units that are secured to each other and mounted on a base.
These and other objects of the invention will be apparent from an examination of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a display stand embodying features of the present invention;
FIG. 2 a rear side elevational view of the structure illustrated in FIG. 1;
FIG. 3 is a top plan view of the structure illustrated in FIG. 1;
FIG. 4 is a partial horizontal sectional view taken on line 4--4 of FIG 1; and
FIG. 5 is an exploded isometric view of the structure illustrated in FIG. 1.
It will be understood that, for purposes of clarity, certain elements may have been omitted from certain views where they are believed to be illustrated to better advantage in other views.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings for a better understanding of the invention, it will be seen that the display stand indicated generally at DS in FIGS. 1 and 5 is formed from a pair of generally hollow, vacuum formed, molded plastic, front and rear units 8 and 50, respectively, which are secured to each other and mounted on 8 base 80, in 8 manner hereinafter described.
The front and rear units are each relatively hollow structures that are preferably made from vacuum formed, molded plastic material. As best seen in FIG. 5, front unit 8 is generally semi-cylindrical in shape and includes a flat, vertical, rear wall 10 and an integral, curved, vertical, front wall 12 extending forwardly from opposed side edges of the rear wall.
The upper and lower ends of the front unit are enclosed by a pair of flat, horizontal, semi-circular top and bottom walls 14. Within the front unit are another pair of flat horizontal, semi-circular, integral, upper and lower inner walls 16 and 18.
Upper inner wall 16 is located a relatively short distance below top wall 14 and defines, with top wall 14, an upper illuminated compartment 17 that is open at the front and rear and that communicates with a related, adjacent, upper compartment 59 of the rear unit 50, as hereinafter described.
Lower inner wall 18 is located approximately midway between top and bottom walls 14 and defines, with upper inner wall 16, a central illuminated compartment 19 that is larger than upper illuminated compartment 17 and that is also open at the front.
A light permeable upper sign panel 20 may be removably attached, in any desired manner (not shown), to the front unit front wall 12, so as to cover the front of the opening to the upper compartment 17. Sign panel 20 may be illuminated by a light fixture 24 located in the adjacent, communicating, rear unit upper compartment 59,
A larger, light permeable, preferably 3-D, lenticular, translite, main sign panel 30, mounted in a frame 32, may be also removably attached, by means of VELCRO fasteners 34, to the front unit front wall 12, so as to cover the opening to central compartment 19. The sign panel may be illuminated by a light 36 located at the rear of central compartment 19.
As best seen in FIG. 1, the front unit front wall 12 may also be provided with a recessed compartment 40 for holding and displaying merchandise M or other items. This compartment is located below central compartment 19 and includes a lower wall or shelf 42.
Additionally, there may be provided yet another recessed compartment 44 for holding and displaying literature L or other items. This compartment includes a lower wall or shelf 46 and a front retaining bar or rail 48 .
Turning now to FIG. 5 of the drawings, it will be seen that rear unit 50 of the display stand DS is generally U-shaped, as seen from the top, and includes a center section 52 and a pair of integral side sections 56 extending outwardly from opposite sides of the center section.
As best seen in FIG. 2, center section has an elongated, vertically extending, recessed compartment 53 which is provided with a plurality of integral, vertically spaced, horizontal shelves 54 for holding and for displaying merchandise or other items.
Each side section 56 also has an elongated, vertically extending, recessed compartment 57 which is provided with a plurality of integral, vertically spaced, horizontal shelves 58 for holding and displaying merchandise or other items,
At the upper extremity of rear unit 50, there is an upper compartment 59, which is in communication with front unit upper compartment 17. Compartment 59 is located above the recessed compartments of the center and side sections of the rear unit and has openings in through the center and side sections.
Light permeable upper sign panels 60 and 62 may be removably attached to the center and side units at these openings and may be illuminated by the previously mentioned illuminating device 24, which is located in compartment 59 of the rear unit, and which also serves to illuminate the upper sign panel 20 of the front unit.
The lower portions of the rear unit side sections 56 may also be provided with recesses 63 for receiving non-illuminated, lower sign panels 64,
As best seen in FIG. 5, the open upper end of rear unit upper compartment 59 may be covered and closed by a removable top or cover 66.
Now to describe the assembly of the display stand. After the front and rear units 8 and 50 have been formed, rear unit 50 is attached to a wooden base by means of screws 76 which, as best seen in FIG. 5, extend through a wooden plate 72 and through rear unit horizontal lower flanges 70 into the separate wood base 80.
After the rear unit 50 has been secured to the base 80, the units are moved together, and the rear wall 10 of the front unit 8 is positioned against and adhesively secured to the front surfaces of the rear unit side section compartments 57.
Additionally, elongated, vertically extending fastening beads or strips (not shown) may be attached to the stand to cover the joints between the front and rear units.
Thus, it will seen that the invention provides a unique and extremely attractive, illuminated display stand, for holding and displaying merchandise, literature, and/or other items, that is relatively light weight and economical to manufacture.
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An illuminated, kiosk type, display stand designed for use in holding and attractively displaying various articles of merchandise or other items or materials. The stand is formed of a pair of hollow, molded plastic, front and rear units that are secured to each other and mounted on a separate base unit.
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This is a divisional of application Ser. No. 08/182,036, filed Jan. 14, 1994, now U.S. Pat. No. 5,462,585.
FIELD OF THE INVENTION
The present invention relates to a method and an apparatus for separating gas from a gaseous material preferably in a closed process. The method in accordance with the present invention is especially suitable for chemical processes in the wood processing industry so as to minimize the environmental disadvantages thereof. The apparatus in accordance with the present invention is applicable, for example, for the separation of residual gases of bleaching processes from fiber suspensions of wood processing industry. While the apparatus in accordance with a preferred embodiment of the invention is mainly designed for the discharge of gas, it may also be used for the discharge of fiber suspension bleach towers. The arrangement in accordance with another embodiment of the present invention is preferably applied in the discharge of gas from low consistency pulps, whereby the consistency of the pulp may be even below 5%.
PRIOR ART
There is a number of known gas discharge apparatuses, which have been used for removal of residual gases of a bleaching stage from fiber suspensions. U.S. Pat. No. 4,209,359 discloses a process for separating residual oxygen from pulp which has been bleached with oxygen. The separation apparatus in accordance with said patent is a relatively large vessel, to which the bleached pulp is discharged from a bleaching stage and in which the pulp is treated at a consistency of about 3%. The pulp is supplied to the vessel tangentially, whereby said pulp is subjected to a centrifugal force, which facilitates the separation of gas in a known manner so that a portion of the gas may be discharged directly from this stage. Thereafter the pulp is allowed to flow to the bottom of the vessel, where pulp is mixed for about 30 seconds to 5 minutes with two mixers of different types, of which the upper is used for pumping the pulp axially downwards and the lower is used for pumping the pulp radially outwards, whereby the pulp is brought into a circulating movement, by means of which residual gas is separated from the pulp.
Disadvantages of the disclosed apparatus are, for example, that it is necessary to dilute the pulp to a low consistency merely for the gas discharge and that the process pressure is not utilized in the form of dynamic pressure whereby, when the vessel and the inlet channel are relatively large, the centrifugal force remains small and the gas separation capacity low. As known, bleaching is carried out preferably at a consistency of about 10 to 12%, whereafter the bleached pulp is led to a washing stage either directly or through a gas separator. If residual gas is not separated from the pulp prior to washing, said gas in the pulp complicates the washing and weakens the washing result considerably. A number of washer types are known in the industry, to which pulp may be supplied at a so called MC consistency (medium consistency), whereby also gas should be removed from the pulp at the MC consistency. Washers operating at the MC range are, for example, diffusers, belt washers and so called DD washers. If it is necessary to dilute the pulp prior to the washing for removal of gas, larger amounts of liquid must be pumped to the washing than if the consistency is maintained original. For example, when the consistency is 3%, there is about 30 kg water in the pulp for each fiber kilogram. When the consistency is about 12% the amount of water has decreased to about 5 kg per a kilogram of fibers. Thus, when the consistency quadruples the amount of the water decreases to one sixth of that of the low consistency. In other words, the dilution of pulp results in that, if MC washers are used, the pulp must be thickened again or alternatively low consistency washers must be used, for example, a suction drum filter, whereby the amount of water--in a way excessive--to be pumped to the washer is sixfold. Moreover, the arrangement in accordance with the disclosed publication has several portions of the apparatus exposed to the atmosphere, whereby the treatment of pulp does not take place in a hydraulically closed pressurized system. FIG. 6 discloses the process of said patent specification illustrating a bleaching tower 36, a gas separator 10 and a filter 46 which are all open unpressurized apparatuses. They allow the contact between the pulp and the air and thus result in foaming and odor problems.
U.S. Pat. No. 4,362,536 discloses an apparatus, by means of which gas may be removed from the pulp flowing in a channel prior to its free fall to a pulp vessel or the like member. The separation of gas is carried out in such a way that the gaseous pulp tangentially enters the separation apparatus, in which a rotatable rotor accelerates the rotational speed of the pulp and the gas is separated due to a centrifugal force to the center of the apparatus, from where it is removed. Gas is prevented from entraining the pulp by using baffle plates. The rotor is not designed to increase the pressure of the pulp, since it is not necessary when the pulp is allowed to fall freely to the vessel below. The apparatus is not applicable in a closed process, which requires a controlled gas discharge allowing fluctuation in pressure and a pressurized pulp discharge. Also the correct pressure difference between the entering pulp, the pulp to be discharged and the exiting gas must be maintained. It is also preferable to be able to increase the pressure of the exiting pulp in the gas separator, which is possible with the apparatus in accordance with the present invention, by means of which it is possible to decrease the pressure level of the reaction vessel and thus decrease the investment costs, unless it is necessary to further transfer the pulp with a pump. It has been possible to eliminate the disadvantages of both the apparatuses and the methods of the above mentioned prior art references with an apparatus in accordance with international patent application WO90/13344 of A. Ahlstrom Corporation, which apparatus is located in the outlet of a pressurized pulp treatment reactor or the like or in the flow channel extending therefrom. The rotor of said apparatus is preferably formed of a rotationally symmetric casing, which is concentrically attached to a flange located substantially perpendicular to the axis of the rotor, and on the flange end thereof there are openings for the discharge of the gas-free suspension towards the discharge opening. Said arrangement is described more in detail in FIG. 1 and in the description thereof. It is typical of the method and apparatus in accordance with said patent application that gas may be separated from medium consistency pulp by disposing the apparatus in accordance with the application in the outlet of a closed reactor and the apparatus itself carries out the discharge of the reactor, the gas separation allowing the fluctuation in pressure and feeds the pulp further at an increased pressure. Due to its construction and control said apparatus can discharge gases without any pulp fibers entrained in them even if the pressure in the reaction vessel varies. The operation of the apparatus includes therefore both the gas separation and the purification of gas. The fibrous material separated in the purification of gas is recirculated through a gas separation apparatus to the pulp flow. A preferred embodiment of the gas separation apparatus carries the specific feature that it can increase the pressure of the exiting pulp.
Said prior art apparatus may still be developed to enable the utilization of pressure in said pulp vessel for the gas separation.
DISCLOSURE OF THE INVENTION
The object of the present invention is to eliminate or minimize the problems occurring in the apparatus in accordance with U.S. Pat. No. 4,209,359. The aim of the process and apparatus in accordance with our invention is to treat the pulp in an as air-free space as possible. In other words by pressurizing the apparatus gas is prevented from mixing with the pulp and by removing gas from the pulp, the disadvantages of the gas in the process are minimized.
Thus it is characteristic of the invention that an apparatus is provided in the discharge/flow channel for pulp, the purpose of which is to convert the process pressure to dynamic pressure and to pass the pressurized pulp suspension being discharged from the vessel to circulate along the inner surface of the flow channel at as high speed as possible, whereby due to a strong centrifugal force gas is separated from the pulp very efficiently and it may be discharged from the apparatus in a manner known from the prior art apparatus. Further it is characteristic of the invention that pulp is discharged under pressure from the apparatus so that the pulp may be directly supplied to the next treatment apparatus with the pressure of the gas separator.
The method in accordance with the present invention is characterized in that
the pressure difference between the inlet channel and the gas discharge is converted to kinetic energy by turning the direction of flow of material to a spiral rotational movement in the inlet channel;
gas is separated from the material to the center of the separation apparatus by means of the created strong centrifugal force;
gas is discharged to a separate further treatment; and
the kinetic energy of the circulating flow of material is converted back to pressure energy.
It is characteristic of the apparatus in accordance with the present invention that in the inlet channel for the material or communicating with such there are means for converting the pressure difference between the inlet channel and the gas discharge to kinetic energy of material, in other words to a circulating movement of the material.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described below, by way of example, with reference to the accompanying drawings, in which
FIG. 1 illustrates a preferred embodiment of an apparatus as described in the international patent application PCT/FI90/00085 of A. Ahlstrom Corporation;
FIG. 2 illustrates another apparatus in accordance with the prior art, as it is in said patent application of A. Ahlstrom Corporation;
FIG. 3 illustrates an apparatus in accordance with a preferred embodiment of the present invention;
FIG. 4 illustrates an apparatus in accordance with a second embodiment of the present invention;
FIG. 5 illustrates an apparatus in accordance with a third embodiment of the present invention;
FIG. 6 illustrates an apparatus in accordance with a fourth embodiment of the present invention;
FIG. 7 illustrates a preferred process embodiment of the method in accordance with the present invention; and
FIG. 8 illustrates another process embodiment of the method in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to FIG. 1 a gas separation apparatus 2 in accordance with the prior art comprises three main portions: a rotor 10, a casing 50 of the rotor and a body 70 of the separation apparatus. Rotor 10 again comprises a first sleeve 16 and a second sleeve 18 mounted on a shaft 12. A flange 20 extends substantially radially from sleeve 16, said flange being provided on one side, the so-called rear side, with a number of rear blades 22 rotating in a so-called second separation chamber. The front side of flange 20 is provided with a number of blades 24, which are supported by rings 26 and 28. In other words, blades 24 form an axially or radially changing, rotationally symmetric shell 118. It is characteristic of the shell 118 that it is completely open from the center excluding the hub of the rotor (cf. screw 14) and that on the flange end the rotor is provided with openings 112 between the blades, through which openings 112 the pulp flows out of the rotor 10 and the ribs at the inlet channel prevent the pulp from blocking between the inlet channel and the blade.
There are a number of blades 30 extending from said second sleeve 18 of the rotor 10, the front surfaces of which blades are perpendicular to the shaft 12 and are provided with a disc 32 and the front side of said disc 32 is provided with a second series of substantially radial blades 34, which are, however, dimensionally remarkably smaller than the blades 30. The blades 30 and 34 and the disc 32 have been arranged to rotate in a separate chamber 36, in a so-called third separation chamber, which is divided by said disc 32 into two subchambers 38 and 40 said chamber 36 being separated from the rest of the rotor space by a partition wall, which is a part of the body of the separation apparatus. Thus the blades 30 rotate in the chamber 38 and the blades 34 in the chamber 40.
A casing 50 of the rotor 10 comprises an axial inlet opening 52, which extends as an inlet channel 54 following the shape of the rotor 10 towards a preferably spiral chamber 56, which is provided with a discharge opening 58. The inlet opening 54 and spiral chamber 56 form a so-called first separation chamber. The clearance between the inner wall of the inlet channel 54 and the blades 24 of the rotor is within the range of 5-50 mm depending to a large extent on the other dimensions of the gas separation apparatus. The outer side of the wall 60 of the inlet channel 54 is provided with a flange 62, by means of which it is possible to attach the gas separation apparatus either to a pipe line, a bleaching tower or some other applicable place.
The body 70 of the gas separation apparatus 2 comprises a rear plate 72 mounted to the annular flange 64 of the casing, said rear plate 72 being provided with sealing and bearings (not shown) for the shaft 12 of the rotor 10. Additionally, the rear plate 72 forms the rear wall 74 of the chamber 36 of the blade-disc-blade combination extending from the second sleeve of the rotor 10. A machined annular disc 80 forms a ring 76 and a front wall 78 of the chamber 36, the inner side of the annular disc 80 being further provided with a ring 82 in a location radially inwards from the blades 34 but, however, at a distance from the second sleeve 18, the ring 82 extending inside the chamber 34 close to the surface of the disc 32. The purpose of the ring 82 is to prevent the discharge of the medium from the chamber 40 to the space between the disc 32 and the sleeve 18.
The rear wall 74 of the chamber 36 is provided with a gas discharge opening 84, which may be an annular opening between the rear plate 72 and the second sleeve 18. Respectively an opening 86 is provided radially outside the ring 82 on the front wall 78 of the chamber 36, the opening 86 leading to a space 42, a so-called second separation chamber, defined by the rear blades 22 of the rotor and the front wall 78 of the chamber 36. Further, a flow channel 44 is arranged in the flange 20 of the rotor 10 or in the first sleeve 16 to lead the gas separated by the rotor to the space 42. It is preferable that the flow channel 44 is located closer to the shaft than the channel 80.
The apparatus in accordance with the prior art described above is used by mounting the apparatus in the discharge opening of a reaction vessel in such a way that the extended blades of the rotor extend into the vessel to some extent to mix the pulp in the vessel, which pulp in some cases may be even very thick, whereby the pulp flows at the pressure of the vessel through the inlet opening 52 of the apparatus to the inlet channel, in which the pulp is exposed to the rotational effect of the rotor 10. Since the rotor at least partially fluidizes the pulp and is able to accelerate the rotational speed of the pulp close to its own rotational speed, the pulp is able to be pressed more freely due to the centrifugal force against the rotor and the wall of the inlet channel to form an annular layer, whereby the gas separating from the pulp has ideal conditions to accumulate as bubbles and to drift towards the lower pressure in the center of the rotor. At the same time the rotational energy caused by the rotor in the pulp and the centrifugal force generating therefrom enables the increase of the pressure of the pulp at the outlet opening 58 compared with the inlet opening 52. Since the pressure is at its lowest close to the flange 20 around the sleeve 16 gas accumulates there and is discharged therefrom through the flow channel 44 to the space 42 behind the flange 20. Some pulp is also discharged with the gas to the space 42, whereby the purpose of rear blades 22 in said space 42 is to pump the pulp possible entrained in the space 42 back to the spiral chamber 56. The gas flows from the space 42 either due to pressure in the space or due to suction connected to the gas separation system through a gap between the annular disc 80 and the second sleeve 18 to the effective range of the blades 30, from where it flows further through a gas discharge opening arranged close to the sleeve 18 either directly to the atmosphere or, if further gas treatment is desired, to a treatment apparatus or a recovery system. The purpose of the blades 30 is to ensure that even if fibers still entrain with the gas flow through the gap between the annular disc 80 and the second sleeve 18 to the chamber 36, the blades 30 pump the pulp through the subchamber 38 around the outer edge of the disc 32 to the subchamber 40 and further through the opening 86 to the space 42, wherefrom the rear blades 22 pass the pulp further to the spiral chamber 56. Blades 30 in the subchamber 38 develop a greater pressure than the pressure prevailing at the opening 86 in the chamber 42, whereby the blades 30 in fact return the pulp through the chamber 40 to the chamber 42. The purpose of the blades 34 is merely to prevent the pulp in the subchamber 40 from densifying and forming lumps in the subchamber 40 by generating a sufficient turbulence in the pulp in the subchamber 40. Further, the purpose of the blades 30 and 34 is to make the gas separation apparatus as insensitive as possible to pressure fluctuations in the spiral chamber or in the inlet channel, in other words to ensure that the gas discharge channel from the separation apparatus is always open without any fibers in any case entering the gas discharge opening 84 in the rear plate 72.
FIG. 2 illustrates a second gas separation apparatus 2 in accordance with the prior art, which apparatus is in principle similar to the apparatus in FIG. 1 excluding the flange 20. In the apparatus of FIG. 2, the front surface of the flange, i.e. the side by the blades 24, is provided with a few blades 46. The construction and operational principle of the blades 46 correspond to the construction and operational principle of the blades of a centrifugal pump. Their purpose is to feed the pulp from inside the shell formed by the blades 24 towards the spiral chamber 56 and further towards the discharge opening 58. Another purpose of the blades is connected with the location of the gas discharge openings and the gas removal process. Said gas discharge openings are preferably located in a dead space gathering air to the rear side of the blades. Said blades may also extend as far as to the inside of the spiral chamber 56. By increasing the number of said blades or the length thereof it is possible to improve the pressure increasing effect of the separation apparatus, which comes into question, when using the apparatus as a discharge apparatus of a bleaching tower for feeding the bleached pulp directly to the washer.
The embodiments of the apparatus in accordance with the invention with their variations illustrated in FIGS. 3-6 are up to the flange 20 identical with prior art apparatus considering the drive side of the apparatus (cf. the apparatus illustrated in FIGS. 1 and 2). FIG. 3 illustrates an apparatus in accordance with a preferred embodiment of the invention, which substantially differs from the apparatus in accordance with the prior art described above in the portion below the flange 20, i.e. by the inlet channel 54. The apparatus communicates by means of said inlet channel with the fiber suspension inlet channel, the discharge opening of a reaction vessel, or the like member. Said apparatus is designed for the treatment of a low consistency pulp or the like, in other words pulp, which does not tend to form a fiber matting clogging the flow channel when flowing, but flows almost like water. It is typical of the apparatus that the inlet channel 54 thereof is formed of at least one spiral flow channel 120 (the drawing illustrates two threads one within the other and thus two spiral flow channels), by means of which the pressure energy of the pulp being discharged to the apparatus due to the pressure difference, is converted to kinetic energy, which further due to the round shape of the cross-section of the inlet channel 54, results in a flow almost parallel to the rim and in generation of a strong centrifugal force by means of which the gas in the pulp is separated efficiently to the center of circulating flow. One method of arranging the spiral flow channel 120 is to mount one or more overlapping spiral strips 122 to the wall of the cylindrical inlet channel 54, the strips being restricted on the side of the shaft 124 of the apparatus to a stationary, relatively small cylindrical surface 126, whereby the cross-section of the flow channel(s) 120 is shaped rectangular. The inlet channel 54 of the apparatus is connected to a larger spiral casing 128 already known from, for example, a centrifugal pump, the front wall 130 of which having a number of guiding blades 132, the purpose of which is to slow down the speed of the pulp flow circulating along the thread and to increase the pressure for the discharge of pulp in a pressurized state from the apparatus. As in all other embodiments, the pulp is allowed to be discharged from the apparatus axially to the inlet channel where there is a surface (thread strips) inclined relative to the discharge direction, by means of which surface the axial movement of the pulp is turned to a circulating flow parallel to said surface. The operation of the apparatus may be illustrated as follows:
pressure energy→kinetic energy→pressure energy,
in other words pressurized fiber suspension is supplied to the apparatus, the pressure is converted to kinetic energy, in other words circulating movement, which again at the end of the separation process is converted back to pressure energy, whereby the suspension exiting from the apparatus has a certain pressure.
The gas separated to the center around the shaft 124 of the apparatus, or the cylindrical surface 126 corresponding to the shaft, is discharged through openings 44 in the flange 20 to the space behind said flange, the openings 44 being located relatively close to the shaft 124 of the flange 20 of the rotor 10 disposed in the spiral 128. The following separation process of gases and fibers corresponds to what is described in our above described WO patent application. It is appreciated from the described apparatus that its construction is the simplest in the product family, and in said apparatus only the flange 20 of the rotor and the portion behind it are used for the separation of fiber suspension flowing through the gas discharge openings 44 to the rear side of the flange 20 from the gas being discharged.
FIG. 4 illustrates an apparatus of the next technical development, in which the frontside of the flange 20 of the rotor 10 is provided with pumping blades 46, which replace the guiding blades 132 disclosed in FIG. 3 and by which the pressure of the pulp exiting from the apparatus is raised, if the discharge pressure reached with the embodiment of FIG. 3 is not high enough. Further, FIG. 4 illustrates with broken lines auxiliary blades 134 on the front side of the rotor 10 of the apparatus for accelerating the rotational speed of the pulp. A precondition for the use of the auxiliary blades 134 is that the circumferential speed of the auxiliary blades 134 is higher than the rotational speed of the pulp rotating in the inlet channel 54. Moreover, said auxiliary blades 134 may, of course, be replaced by axial extensions 136 of the blades 46 of the flange 20 of the rotor 10 (also shown with broken lines), whereby blades 46, 136 are thus continuous, or both the axial extensions 136 and the auxiliary blades 134 may be used. The operation of the apparatus may be illustrated as follows:
pressure energy→kinetic energy+additional energy→pressure energy,
in other words by introducing additional energy the separation of gas from pulp is facilitated and on the other hand the discharge pressure is raised. By adjusting the feed of the additional energy, for example, by dimensioning of auxiliary blades 134 or by changing the rotational speed, it is possible to adjust the amount of gas being separated in the apparatus and the energy consumption of the auxiliary blades reasonable.
FIG. 5 illustrates an apparatus in accordance with a more complicated embodiment, which is already designed for treating pulps which may form a fiber matting liable to clog the flow channel. In other words the consistency of the pulp may vary between 8 and 18 percent or sometimes even exceed it. Then the basic principle is that at least one of the walls of said flow channel is movable thus preventing the accumulation of fibers to a fiber matting. In an embodiment in accordance with the drawing the center of the flow channel 54 is provided with an extension 138 of the rotor 10, which may be a pipe or a closed space with a substantially smooth surface but it is possible to provide the surface with small protrusions, which more efficiently keep the pulp in a turbulent movement close to the surface and prevent the clogging of the flow channel. The end of the extension 138 of the rotor is preferably provided with blade-like members as shown in FIG. 5, which preferably extend to the inside of the pulp vessel in order to fluidize the pulp. At least one spiral strip 140, extending radially from the extension 138 of the rotor 10 to the wall of the inlet channel 54, is attached to the wall of the flow channel 54. Said construction ensures that the pressure difference between the spiral housing 128 of the apparatus and the inlet channel (not shown) is not able to level down at least along the wall of the inlet channel 54, but only between the extension 138 of the rotor 10 and the spiral strip 140, because, of course, a reasonable clearance must be maintained between the extension 138 and spiral the strip 140 in order to avoid mechanical contact. Also it must be noted that although the drawing shows only the blades 46 of the flange 20 of the rotor 10, they may either continue axially inside the inlet channel 54, or the inlet channel 54 may be provided with auxiliary blades, as already shown in FIG. 4.
FIG. 6 illustrates yet another, the most complicated, embodiment in accordance with the present invention, in which a thread 150 is mounted on an extension 152 of the rotor 10 in such a way that the clearance between the wall thread 150 and the wall of the inlet channel 54 is adjusted as small as possible, at least at the end of the thread 150 by the flange 20 of the rotor 10. The thread 150 may be made equally "sealed" throughout the distance, in other words with equally small clearance, if the pressure difference between the inlet channel (not shown) and the spiral housing 128 is not very large, but it may also be designed to equalize the pressure differences to some extent, for example, in such a way that the pressure is allowed to evenly decrease within one or tow pitches of the thread 150. In other words the thread is allowed to leak to some extent in order to allow a gradual decrease of pressure. The extensions 136 of the blades 46 are added in FIG. 6, which extensions are disclosed as alternatives to auxiliary blades 134 shown in FIG. 4. However, the same precondition concerns the extended blades 136 as the auxiliary blades 134, i.e. The circumferential speed of the blades 136 must be higher than the rotational speed of the pulp. It may still be appreciated from FIG. 6 that the rotational direction of the rotor 10 illustrated with an arrow with unbroken line is not the same as the rotational direction of the pulp in the spiral flow channel 154 of the inlet channel 54. In the situation described with an arrow with broken line the rotational direction of pulp is the same as the rotational direction of the rotor. However, it must be emphasized that the apparatus operates in both cases. In the drawing in the case shown with an arrow with unbroken line the circumferential speed of the pulp is less than in the case when the pulp circulates in the rotational direction of rotor 10 (the arrow with broken line). thus it is clear that by changing the rotational direction of the rotor or preferably by making the threads either right-handed or left-handed respectively it is possible to increase or decrease the circumferential speed of the pulp. At high pressure differences it is preferable to slow down the rotational speed of the pulp in this manner. When considering the operation of the apparatuses it must be born in mind that the right- or left-handedness always determines the rotational direction of the pulp also when the pulp is discharged, regardless of what the rotational direction of the rotor is. The embodiment in FIG. 6 is provided with an extension 156 which is at least nearly axial and extends to the inlet channel of the thread 150 or possible to the pulp vessel and its purpose is to generate turbulence in the inlet channel or in the pulp vessel to facilitate, similarly to the blade-like members shown in FIG. 5, the flow of the pulp to the inlet channel 54 and to readily lead the flow of the pulp from axial to spiral. Finally it may also be stated of the embodiment of FIG. 6 that it is not always necessary to have a thread operated by the extension of the rotor, but, of course, also a separately operated thread is possible.
It is characteristic of all the embodiments described above that the angle of the thread, the so-called flow angle, i.e. the angle between the thread and the level cutting the inlet channel perpendicularly is less than 30 degrees, preferably less than 15 degrees and most preferably less than 10 degrees.
The apparatus in accordance with the present invention operates as described above in connection with the different embodiments. How the gas separated to the center of the apparatus is discharged, is already described above in the WO patent application of A. Ahlstrom Corporation mentioned as prior art.
EXAMPLE 1
Gas Separation Apparatus
When a pressure of about 5 bar prevails in the pulp vessel, it is possible to convert it to a rotational movement, the speed of which is about 22 m/s. Respectively, it may be considered that the rotational speed of the rotor of the gas separator, which is required for preventing the clogging of the pulp being discharged from the mass tower, is about 1500 rpm, resulting in that the circumferential speed of the rotor having a diameter of 150 mm is about 11.8 m/s. It is appreciated that if the rotational direction of the pulp determined by the rotor is the same as the rotational direction of the rotor, the circumferential speed of the pulp is about 34 m/s and if the rotational direction of the rotor is against the rotational direction of the pulp, the circumferential speed is about 10 m/s.
FIG. 7 illustrates a preferred application of an apparatus in accordance with the present invention. The schematic illustration describes the flow of the pulp from a cellulose pulp vessel 90 pumped by an MC® pump 92 through a feed mixer 94 for bleaching chemical (e.g. O 2 , O 3 , Cl, ClO 2 ) to a bleaching tower 96, the discharge end of which is provided with a gas separation apparatus 2 in accordance with the present invention. In the preferred embodiment of FIG. 7 the discharge of pulp from the tower 96 is preferably carried out by said separation apparatus 2 in such a way that the extension, or extensions if two threads set one within the other are used, of the thread of the rotor 10 extending to the discharge opening of the tower fluidize(s) the pulp and enable(s) the discharge thereof to the separation apparatus, the blades 46 of which again raise the pressure of the bleached suspension in such a way that it may be supplied directly without any separate feed means to a washer 98, which may be either a pressure diffuser or a so-called MC® drum washer.
The method in accordance with the present invention is described more in detail with reference to FIG. 7, in which pulp is pumped by a pump 92 to a chemical mixer 94, a reactor 96, a gas separator 2 and a washer 98. The whole process is carried out in a closed space without any contact between the air and the pulp. All means are pressurized and closed. Gas separation apparatus 2 operates partially as a pump, whereby the pressure of the pulp is raised prior to the washer. The washer is pressurized and closed. It is preferable to carry out the whole treatment at the same consistency, most preferably at the range of 8 to 20%.
In order to realize the method some of the apparatus required already exist and other necessary equipment are being developed. The high consistency pump 92 necessary in the process, an MC® pump, is disclosed, for example, in U.S. Pat. No. 4,780,053. Japanese patent 1617019 discloses a chemical mixer. A pressurized washer is disclosed in U.S. Pat. No. 4,952,314. A gas separation apparatus essential in the method is illustrated above with reference to FIGS. 3-6.
FIG. 8 illustrates another application of the apparatus in accordance with the present invention, in which pulp is pumped from a temporary pulp vessel 90 by an MC® pump 92 through a feed mixer 94 of bleaching chemical (e.g. O 2 , O 3 , Cl, ClO 2 ) to a bleaching tower 100, the discharge of which is carried out by means 102 known per se to a drop leg 104, which is preferably provided with a gas separation apparatus 2 in accordance with the embodiment of FIG. 6. Also in this case the separation apparatus feeds the pulp directly to the washer. The apparatus in accordance with the present invention may be used in pressurized, but also in open unpressurized processes, which, of course, results in the use of a high rotational speed in order to obtain a sufficient circumferential speed and centrifugal force. It must also be noted that although bleaching chemicals are mentioned above, also other substances and organisms used, and to be used in the future, in the treatment of fiber suspension, such as enzymes of fungi, are also covered. Thus the term "chemical" in the above description must be understood in a broader sense than what is conventionally understood by said term "chemical".
It must also be noted that the spiral rotational movement of pulp may be brought about also by constructions other than a thread. It may be considered that, for example, a number of nozzles are mounted partly tangentially, partly axially to the rotationally symmetric member so that the pulp is discharged through the nozzles into said space converting the pressure energy to kinetic energy. It is, of course, possible to arrange into said member the thread illustrated in the previous embodiments if so desired, or a rotatable rotor, if it is considered necessary. Said member with its flange means again may be connected to a spiral housing described in connection with the previous embodiments.
As is appreciated from the above disclosed embodiments, a new gas separator type has been developed, which generally speaking and regardless of the above description of the applications concentrated on wood processing industry, is applicable in all apparatus in which gas must be separated from a material behaving like a liquid. The apparatus is very suitable for the wood processing industry, for example, because it is able to treat very solid and weakly flowing materials and additionally, beside the primary object, is able to discharge the bleaching tower very efficiently and in an energy saving way, if so desired, and to feed the pulp directly to the washer. However, it must be noted that the method and apparatus in accordance with the present invention may may be applied also in apparatus where it is not necessary to utilize its discharge or pumping ability. Thus the above described embodiments must not be seen as restricting the scope and protection of the invention, but merely exemplifying a number of most preferred construction alternatives and applications. Thus all details illustrated in connection with different embodiments such as auxiliary blades, extensions of blades, extensions of shafts, clearances, etc. may be used, where applicable, in all embodiments where they are not explicitly mentioned. It is also not characteristic of the present invention that, although the term "spiral housing" is used throughout the whole patent application, said portion is specifically spiral, but also other forms applicable in the particular use or purpose may come into question. The scope of protection of the present invention is disclosed and determined by the enclosed claims, alone.
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Gas is separated from fluent material, particularly a liquid or a cellulose fiber suspension having a consistency of about 8-18%, utilizing a closed separation apparatus having a spiral housing with a central axis, a fluent material inlet channel, a fluent material outlet, and a gas outlet. A pressure differential is maintained between the inlet channel and the spiral housing, and the pressure differential is converted to kinetic energy of the fluent material by causing the fluent material to flow through one or more spiral flow paths through the inlet channel toward the spiral housing. In the spiral housing a rotor is rotated to impart a strong centrifugal force to the fluent material to cause gas to separate and collect adjacent the central axis of the spiral housing, from which the gas is removed. The strong centrifugal force caused by the rotating rotor discharges the fluent material through the outlet. The spiral flow paths rotate with the rotor in the spiral housing.
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FIELD OF THE INVENTION
[0001] This invention relates to methods and devices for detecting frequency modulated signals.
BACKGROUND OF THE INVENTION
[0002] A frequency modulated signal consists of a predetermined sequence of data bits (Dbits), where each Dbit type is transmitted as a signal having one or more frequencies from a predetermined set of specified frequencies. Use of a frequency modulated signal to transmit information over a communication line requires a detector capable of quickly detecting the signal even in a low signal to noise ratio environment.
[0003] For example, communication devices are known capable of transmitting and receiving voice as well as video signals. When a voice communication link has been established between two or more patties, and one of the parties decides to change the mode of communication from voice to video, the party transmits a Cl (call indication) signal to the other party's device in order to inform the other party's device to change its mode of communication from voice to video. This CI signal is specified in the 1TU-V.8 standard, and is a frequency shift modulated signal known as the “T 1 -N 0 ” sequence. This sequence consists of 10 ones (‘1111111111’) followed by 10 synchronization bits (‘0000000001’) and a call function octet (‘0 byte data 1’). The standard further specifies that a “0” be transmitted as a 1180 Hz signal, and that a “1’ be transmitted as a 980 Hz signal. These two frequencies, 980 Hz and 1180 Hz are referred to as the “FSK” (frequency shift key modulation) frequencies. The CI signal is transmitted with a regular ON/OFF cadence in which the ON periods are not less than 3 periods of the CI sequence, and are not greater than 2 sec in duration. The OFF periods are not less than 0.4 sec and not greater than 2 sec in duration.
[0004] A communication device capable of alternating between voice and video modes needs to include a CI signal detector, also known as a CI detector. When the CI detector identifies a CI signal received at the communication device from a remote communication device indicating that the remote device has changed from voice to video communication, the CI detector generates a signal causing its communication device to change from voice to video communication.
[0005] As another example, dual frequency (DF) signals, also known as dual-tone multiple frequencies (DTMF), are signals that are an additive combination of two equal-amplitude frequency components. Thus, the signal generated by depressing “1” on the telephone keypad is the sum of a 697 Hz and a 1209 Hz frequency signals, and the signal generated by depressing “5” is the sum of a 770 Hz and a 1336 Hz sine wave. DF signals are used for example, for representing telephone numbers and other signaling functions within a telephone system including interactive voice response.
SUMMARY OF THE INVENTION
[0006] The present invention provides a device for detecting a multi-frequency signal in a communication signal. The device of the invention may be used for example, as a CI signal detector for detecting a CI signal in a communication signal. The CI detector may be used in a communication device capable of supporting voice and video communication. As another example, the multi-frequency detector of the invention may be used in a device to detect a DTMF signal.
[0007] In the multi-frequency detector of the invention, an input signal which is to be analyzed for the occurrence of a predetermined signal sequence of data bits is input to a filter module. In accordance with the invention, the filter module carries out a band pass filtering process in which the passed frequency band includes all of the frequencies in the specified frequency set consisting of all of the frequencies used to represent the Dbits in the signal sequence to be detected. In a preferred embodiment of the invention, the passed frequency band has a plateau around each one of the frequencies in the frequency set, where adjacent plateaus are preferably separated by a local minimum.
[0008] The filtered signal is input to a frequency condition module that determines, on the basis of the detector module output whether the frequency of the filtered sequence is one of the specified frequencies. When one of the specified frequencies is detected, by the frequency condition module, it generates an output of the Dbit corresponding to the detected frequency. Otherwise the module generates a blank output (indicated herein by “n”) indicating that none of the specified frequencies was detected. A sequence condition module may optionally search the output of the frequency condition module for the presence of the signal sequence to be detected. When the signal sequence is detected, the device generates a signal indicating that the signal sequence has been detected.
[0009] Thus, in one of its aspects, the present invention provides a method for detecting in a single or multi frequency signal, one or more frequencies from a predetermined set of frequencies, comprising:
[0010] (a) subjecting the signal to a complex filter substantially passing all of the frequencies in the predetermined set of frequencies, to produce a complex filtered signal;
[0011] (b) for each of one or more pairs of members of the complex filtered signal, determining a complex number Y d having a phase indicative of a phase difference between the two members of the pair; and
[0012] (c) determining the frequency of the signal based upon the one or more complex numbers determined in step (b).
[0013] In another of its aspects, the invention provides a device for detecting in a single or multi frequency input signal, one or more frequencies from a predetermined set of frequencies, the device comprising a processor configured to:
[0014] (a) subject the input signal to a complex filter substantially passing all of the frequencies in the predetermined set of frequencies, to produce a complex filtered signal; for each of one or more pairs of members of the complex filtered signal (a+bj) and (c+dj):
[0015] (b) determine a complex number Y d having a phase indicative of a phase difference between the two members of the pair; and
[0016] (c) determine the frequency of the signal based upon the one or more complex numbers determined in step (b).
[0017] In still another of its aspects, the invention provides an apparatus comprising the device according to the invention.
[0018] In yet another of its aspects, the invention provides a device comprising a processor configured, for each of the two or more communication lines, to:
[0019] subject a single frequency input signal in the communication line to a complex filter substantially passing all of the frequencies in the predetermined set of frequencies, to produce a complex filtered signal; for each of one of more pairs of members of the complex filtered signal (a+bj) and (c+dj):
[0020] determine a complex number Y d having a phase indicative of a phase difference between the two members of the pair;
[0021] determine the frequency of the input signal based upon the one or more complex numbers determined in step (b);
[0022] for each of the one or more predetermined frequencies, output a Dbit value associated with the predetermined frequency if the current frequency of the filtered signal is equal to the predetermined frequency;
[0023] output a Dbit value of n if the current frequency of the filtered signal is not equal to any one of the predetermined frequencies to generate a sequence of Dbits;
[0024] analyze the sequence of Dbits to detect the T 1 -N 0 sequence: and
[0025] connect the communication line to the modem when the T 1 -N 0 sequence is detected in the communication line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] In order to understand the invention and to see how it may be carried out in practice embodiments will now be described, by way of non-limiting example only with reference to the accompanying drawings, in which:
[0027] FIG. 1 shows a CI signal detector in accordance with one embodiment of the invention;
[0028] FIG. 2 shows a frequency response of a filter module for use in the CI signal detector of FIG. 1 ;
[0029] FIG. 3 shows a method carried out by the energy condition module for use in the CI signal detector of FIG. 1 ;
[0030] FIG. 4 shows the normalized phase difference between two consecutive Outputs from the filter module as a function of the frequency of the filtered signal;
[0031] FIG. 5 shows a method for determining whether the phase difference between two consecutive outputs from the filter module is in a predetermined range;
[0032] FIG. 6 shows an implementation of a call indicator detector at a multi line communication node; and
[0033] FIG. 7 shows a DTMF detector in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0034] The invention will first be described within the context of a CI signal detector configured to detect the T 1 -N 0 signal sequence in a frequency modulated signal composed from two different Dbit types (0 and 1). This is done only for clarity in the description; it being evident that the invention may be extended to the detection of a frequency modulated signal composed from more than two Dbit types.
[0035] FIG. 1 shows a schematic representation of a CI signal detector, generally indicated by 2 , in accordance with one embodiment of the invention. An input signal 4 which is to be analyzed for the presence of the T 1 -N 0 sequence is first input to a filter module 6 . As described in detail below, the filter module 6 carries out a filtering process in which frequencies around the two FSK frequencies used in a CI signal are transmitted. The output 8 of the filter module 6 is a sequence of complex numbers that is input to an energy condition module 10 . The energy condition module 10 determines whether the present value of the sequence 8 has an energy level above a predetermined threshold value. If the present value of the sequence 8 does not have an energy level above the predetermined threshold, this result is input as a signal 11 to a sequence condition module 20 which outputs a result 22 that a CI signal has not been detected. If the present value of the sequence 8 has an energy value above the predetermined threshold, the present value of the sequence 8 is input to a frequency detection module 12 as a signal 13 . The energy condition module then determines whether the sequence 8 has had an energy level above the predetermined threshold for at least a predetermined number of consecutive values. If the energy condition module 10 determines that the filtered signal does not meet this energy criterion, this result is input to the sequence condition module 20 which outputs a result 22 that a CI signal has not been detected.
[0036] When the energy condition module 10 determines that the filtered signal 8 satisfies the energy criterion, this is input to the frequency detection module 12 which generates, for each pair of consecutive complex values output from the filter module 10 , a complex output whose phase is equal to the phase difference between the pair. The output 14 of the frequency detector module is input into a frequency condition module 16 that determines from its input, whether the frequency of the filtered signal 8 is one of the two FSK frequencies. When the 980 Hz frequency or the 1180 Hz frequency is detected by the frequency condition module 16 , the module 16 generates an output 18 of “1” or “0”, respectively. Otherwise the module 16 generates a blank output “n” indicating that neither one of the FSK frequencies was detected. The sequence 18 generated by the frequency condition module is input to a sequence condition module 20 which searches the sequence 18 for the presence of the T 1 -N 0 sequence. The sequence condition module outputs an output 22 that is set to 1 when the T 1 -N 0 sequence is detected. Otherwise, the output 22 is set to 0.
The Filter Module
[0037] FIG. 2 a shows the frequency response of the filter module 6 in accordance with one preferred embodiment of the invention. The frequency response has a transmission band 24 including the two FSK frequencies that is shown in greater detail in FIG. 2 b. The transmission band 24 has a plateau 25 a around the FSK frequency 980 and a plateau 25 b around the FSK frequency 1180. The two transmission peaks 25 a and 25 b are separated by a local minimum 27 . The filter module 6 uses an 80 tap complex FIR (finite input response) to compute one complex output every 2 ms. The input signal 4 typically has a baud rate of 300 baud, and a sampling rate greater than 300 baud. For example, a sampling rate of 500 baud may be used, in which case every 16 samples (2 msec) a new FIR starts to run. Every run generates a single complex number indicative of the real and the imaginary frequency components. The frequency response shown in FIG. 2 is achieved using FIR coefficients generated as follows.
[0038] The frequency bandwidth of the filter module 6 is designed to extend from about 100 Hz below the carrier frequency Fc of the input signal 4 (1080 Hz) to 100 Hz above the carrier frequency (with a deviation of up to +/−12 Hz). The input signal 4 is shifted by the carrier frequency Fc by multiplying the input signal 4 by exp(j*Fc), so that the Fc is set to 0 Hz. Low pass filtering is then run with a high attenuation out-band using a Hamming window convoluted with a Kaiser window. The response of this band pass filter is saddle shaped and flattened at the two FSK frequencies. This is accomplished by multiplying by the two symmetric side frequencies near of the carrier frequency (Fc), exp(j*((Fc+df) and exp(j*(Fc−dt).
[0039] In a preferred embodiment the following process is carried out
[0000] Win_size=80; df= 81; Gb=− 0.8; dp=− ½; dw= 16; fc= 1080; Fs= 8000;
[0040] % Make lowpass fir filter.
[0041] Win=conv(hamming(Win_size−dw+1),kaiser(dw,1));
[0042] % Complex shift by:
[0043] expFp=exp(j*2*pi*([1:length(Win)/2]*(fc+df)/Fs+dp*(fc+df)/Fs));
[0044] expFn=exp(j*2*pi*([1:length(Win)/2]*(fc−df)/Fs+dp*(fc−df)/Fs));
[0045] expFc=exp(j*2*pi*([1:length(Win)/2]*(fc)/Fs+dp*(fc)/Fs));
[0046] s=expFp+expFn+Gb*expFc;
[0047] % make symmetric complex freq.
[0048] s=[conj(s(end:−1:1)) s];
[0049] % Calculate complex FIR coedf.
[0050] B=s. *Win′;
[0051] The filter s is converted into a symmetric complex form by setting, s=[conj(s(end:−1:1)) s]. Since the filter module 6 uses a symmetric window, it is sufficient to use only half of the window. The real window is based oil cosines and thus has positive symmetry. The imaginary window is based on sines and thus has negative symmetry. Because of this negative symmetry, the half imaginary window is multiplied by ‘−1’ when being Using it for the other half. A complex FIR coefficient B is calculated as B=sWin′.
[0052] Implementing this process with the parameter values specified above, the filter coefficients B shown in Table 1 in fix point format Q2.13 are obtained.
[0000]
TABLE 1
WinImage_Fix
WinReal_Fix
68,
39,
150,
−51,
93,
−225,
−147,
−299,
−415,
−114,
−447,
294,
−91,
639,
495,
579,
879,
14,
670,
−737,
−121,
−1099,
−986,
−693,
−1250,
300,
−628,
1186,
483,
1278,
1264,
478,
1124,
−595,
268,
−1117,
−561,
−798,
−741,
−82,
−338,
307,
2,
108,
−229,
−196,
−760,
108,
−706,
1075,
489,
1786,
2204,
1080,
2851,
−1181,
1210,
−3533,
−2175,
−3813,
−4933,
−1022,
−4532,
3403,
−492,
6245,
4745,
4897,
7309,
−345,
4846,
−6048,
−1394,
−7988,
−7148,
−4381,
−8192,
2520,
−3566
7898
[0053] Although the filter module 6 uses a time window of including 80 taps, the main coefficient energy is on slightly more than one FSK bit, corresponding to about 30 samples. Using a sliding window with a 2 msec delay gives overlapped FSK bits, for more data.
The Energy Condition Module
[0054] The output 8 from the filter module 6 is a time sequence Of complex numbers that is input to the energy condition module 10 . FIG. 3 shows a flow chart diagram for a method carried out by the energy condition module 10 . In step 26 the value of a counter is set to 0. In step 28 a complex data sample a+bi from the output 8 is input to the energy condition module 10 . In step 30 , the energy of the output 22 is calculated using the algebraic expression Energy=a 2 +b 2 . In step 32 it is determined whether the energy is above a predetermined threshold TH. If no, then in step 33 an output of n is generated to the sequence condition module 20 and the process returns to step 26 with the counter being reset to 0. If the energy is above the threshold TH, then in step 34 the present value of the filtered signal 8 is input to the frequency detector module 12 . The process then continues with step 35 where the value of the counter is increased by 1. In step 36 it is then determined whether the counter is greater than or equal to a predetermined constant N. If yes, then in step 37 an output of 1 is generated to the frequency condition module 16 and the process returns to step 28 with the next data sample being input to the energy condition module 10 . If the counter is not greater than or equal to the predetermined constant N, then in step 38 an output of n is generated to the sequence condition module 20 and the process returns to step 28 with the next data sample being input to the energy condition module 10 .
[0055] The final energy decision is thus based upon the last N outputs from the filter module 6 . The energy of all of the last N outputs must exceed the energy threshold TH in order for an output of 1 to be generated by the energy condition module 10 . The larger the N, the larger the immunity to noise and other signals superimposed on the CI signal. 4 , but there is less sensitivity to “talk off”. N may be set, for example to 4.
[0056] In order to reduce or prevent MIPS (million instructions per second) peaks, the filter module 6 should run every sample, while the other modules (the energy condition module 10 , the frequency detection module 12 , the frequency condition module 16 and the sequence condition module 20 ) run every 2 ms.
The Frequency Detection Module
[0057] When the frequency detection module 12 receives an input from the energy condition module 10 that the energy of the filtered signal 18 has been above the predetermined threshold TH for at least the N most recent data values, the frequency detection module 12 determines whether the frequency of the signal is one of the two FSK signals.
[0058] During a time period when the frequency of the input signal 4 , and hence the frequency of the filtered signal 8 is constant, all pairs of consecutive data values in the sequence 8 have a fixed phased difference α that is uniquely determined by this constant signal frequency and the constant time delay between consecutive data values. There is thus a one-to-one correspondence between the frequency of the signal 8 and the phase difference α. FIG. 4 shows the normalized phase between two consecutive data values in the sequence 8 as a function of the frequency of the signal 8 . In the normalization shown in FIG. 5 , the carrier frequency Fc has been set at 0 phase for the sake of clarity in the description.
[0059] When the delay is 2 msec (16 sample) and Fs=8000 Hz then Fs/16=500 Hz so that every 500 Hz the phase changes sign. In this case, the relationship between the normalized phase and the frequency of the signal 8 in the rage of±250 Hz around Fc is:
[0000]
θ
0
=
2
π
500
*
(
f
0
-
f
c
)
[0060] where f 0 is the frequency of the signal 8 , and f c is the carrier frequency. More generally, for non-normalized phases:
[0000]
θ
0
=
2
π
f
b
*
rem
(
f
0
-
f
b
f
b
)
[0061] where f b is the frequency at which the phase changes sign (the “flip frequency”) Given two consecutive data points in the output 8 , y a =a+bj=Ae jH and y 1 =c+dj=Ce jD , the frequency detector module 12 calculates a vector Y d where Y d =y 0 ·conj(y 1 )=ACe j(H−D) =(a+bj)(c−dj)=g+hj.
[0000] The phase of the vector Y d is thus equal to the phase difference α between the two consecutive vectors y 0 and y 1 . The frequency detector module outputs as an output 14 to the frequency condition module, the vector Y d .
[0062] In a neighborhood of the FSK frequencies, there should not be more than one cycle of the phase because more than one cycle of the phase may cause misdetection. As shown in FIG. 4 , this situation can arise, for example, with a time delay of more than 16 samples, using this 80 tap FIR. A delay of about 2 msec is the optimum delay that an 80 tap filter can support.
The Frequency Condition Module
[0063] The frequency condition module 16 determines whether the frequency of the signal 8 is one of the two FSK frequencies using an algorithm involving the vector Y d . If the phase α of Y d is in a first range TH 1 <α<TH 2 corresponding to a predetermined range of the FSK frequency 980 Hz, the frequency condition module 16 outputs an output 18 of Dbit=1 to the sequence condition module 20 , indicating that the value of the signal 4 is 1. If the value of α is in a second range TH 3 <α<TH 4 , where TH 2 <TH 3 corresponding to a predetermined range of the FSK frequency 1180 Hz, the frequency condition module 16 outputs an output 18 of Dbit=0, indicating that the value of the signal 4 is 0. Otherwise, the frequency detector module outputs an output 18 of Dbit=n.
[0064] In practice, when determining whether α is in a particularly range, it may be computationally more efficient to operate on the real and imaginary parts of Y d , rather than directly on the phase α of Y d . FIG. 5 shows a flow chart for a method of determining, whether the phase difference α is in either one of the intervals TH 1 <α<TH 2 or TH 3 <α<TH 4 that operates on the imaginary part of Y d . In step 46 the vector Y d is rotated by −TH 2 by multiplying Y d by exp (−jTH 1 ). In step 48 , it is determined whether the imaginary part of the rotated vector Y d exp(−jTH 2 ) is less than 0. If the imaginary part of Y d exp(−jTH 2 )is less than 0, then in step 40 , the vector Yd is rotated by −TH 1 by multiplying Y d by exp(−jH 1 ). Then, in step 42 it is determined whether the imaginary part of the rotated vector Y d exp(−jTH 1 ) is greater than 0. If no, then α<TH 1 so that the frequency of the signal 8 is not 980 Hz and is not 1180 Hz. In this case, in step 44 , the frequency condition module 16 outputs an output of Dbit=n to the sequence condition module 20 , and the process ends. If the imaginary part of Y d exp(−jTH 1 ) is greater than 0, then TH 1 ≦α≦TH 2 and the frequency of the signal 8 is 980 Hz. In this case, in step 50 the frequency condition module 16 outputs a databit (Dbit) output of “1”, and the process ends.
[0065] If in step 48 it is determined that the imaginary part of the rotated vector Y d exp(−jTH 2 ) is not less than 0. then in step 52 , the vector Y d is rotated by −TH 3 by multiplying Y d by exp (−jTH 3 ). Then, in step 54 it is determined whether the imaginary part of the rotated vector Y d exp(−jTH 3 ) is greater than 0. If no, then α<TH 3 and the frequency of the signal 8 is not 980 Hz and is not 1180 Hz. In this case, in step 56 , the frequency condition module 16 outputs Dbit=n and the process ends. If the imaginary part of Y d exp(−jTH 3 ) is greater than 0, then TH 3 >α. In this case the process continues with step 58 where the vector Y d is rotated by −TH 4 by multiplying Y d by exp (−jTH 4 ). Then, in step 60 it is determined whether the imaginary part of the rotated vector Y d exp(−jTH 4 ) is less than 0. If no, then α>TH 4 and the frequency of the signal 8 is not 980 Hz and is not 1180 Hz. In this case, in step 62 , the frequency condition module 16 outputs a Dbit=n and the process ends. If the imaginary part of Y d exp(−jTH 4 )is less than zero, then TH 3 <α<TH 4 , and the frequency of the signal 8 is 1180 Hz. In this case, in step 64 the frequency condition module 16 outputs a databit (Dbit) output of “0”, and the process ends.
[0066] When a signal is superimposed on the CI signal, “frequency noise” may cause the phase α of Y d to leave the detection zone. Frequency noise may be reduced by using instead of Y d in the algorithm of FIG. 5 , the mean value of the M most recent values of Y d , where M is a predetermined constant. M may be, for example, equal to 4.
The Sequence Condition Module
[0067] The output 18 of the frequency condition module 16 consisting of the sequence of Dbits is input to the sequence condition module 20 . The sequence condition module 20 searches the output 18 for the preamble of the T 1 -N 0 sequence (the portion of the T 1 -N 0 sequence consisting of 10 ones (‘1111111111’) followed by 10 synchronization bits (‘0000000001’)).
[0068] The fact that there is no synchronization between the sampling rate and the baud rate and the fact that the Dbit is based on an average of a few windows, man cause Dbit misdetection at the beginning of the T 1 -N 0 sequence and in the transition of bits. Thus, for example, when the signal 4 includes the T 1 -N 0 sequence preamble
[0000] . . . n,n,1,1,1,1,1,1,1,1,1,1,0,0,0,0,0,0,0,0,0,1 . . .
[0069] the corresponding output 18 of the frequency condition module 16 may be
[0000] . . . n,n,n,1,1,1,1,1,1,1,1,1,n,0,0,0,0,0,0,0,n,1 . . .
[0070] The distance in the T 1 -N 0 preamble between the first ‘1’ to the first ‘0’ is known as the “flip distance” and is equal to 10 FSK bits or 17 Dbits (The Dbit length is obtained by dividing the FSK bit length by 0.6). The T 1 -N 0 preamble contains 9 flips (a 1 separated from a subsequent 0) of length 10 FSK bits or 17 Dbits. Due to the problem of misdetection, in one preferred embodiment, in order to detect the T 1 -N 0 sequence preamble, instead of searching the output 18 for consecutive flips of length 10 FSK bits, the output 18 is searched for predetermined number of consecutive occurrences of a shorter flip. For example, the T 1 -N 0 preamble maybe detected in the output 18 by searching for consecutive occurrences of a flip of length 7 FSK bits (12 Dbits). When a predetermined number of such flips is detected, the sequence condition module 18 outputs an output 22 of “1” indicating that the T 1 -N 0 signal has been detected. Otherwise, the output 22 is set to 0, indicating that the T 1 -N 0 signal has not been detected.
[0071] The higher the number of consecutive occurrences needed to generate an Output 22 of “1”, the lower die probability for false detection, but the higher the probability for not detecting the T 1 -N 0 sequence preamble when present. On the other hand, the lower the number of consecutive occurrences needed to generate an output 22 of “1” the higher the probability for false detection but the lower probability for not detecting the T 1 -N 0 sequence preamble when present. For most implementations, a value of 7 for the predetermined constant is preferable.
[0072] Since the sequence condition module searches the signal 18 on) and looks for the CI preamble, and the preamble itself is only two thirds of the CI signal, he detection decision is made after no more than 66 mSec from the beginning of the CI.
[0073] FIG. 6 shows an implementation of the CI detector 2 at a communication node 68 of a communication system. The CI detector 2 simultaneously monitors each of two or more communication lines 70 at the node for the occurrence of the T 1 -N 0 sequence. Three communication lines 70 a, 70 b, and 70 c are shown in FIG. 6 . This is by way of example only, and the CI detector 2 may be implemented at a communication node 68 involving any number of lines 70 . The implementation further comprises a single modem 72 . When the sequence condition module 20 ( FIG. 1 ) of the CI detector 2 detects the T 1 -N 0 sequence in one of the communication lines 70 , for example, the communication line 70 a, the CI detector 2 connects the communication line 70 a to the modem 72 by means of a switch 74 and causes the modem to change its mode of communication from voice to video. In this implementation, a single modem may be used, and use of a dedicated modem for each of the communication lines can be avoided.
[0074] FIG. 7 shows an implementation of the multi-frequency detector of the invention in a DTMF detector 80 . The DTMF detector 80 searches an input signal 82 for the presence of a DTMF signal which consists of an additive combination of a high frequency and a low frequency where the high frequency is from a predetermined set of high frequencies and the low frequency is from a predetermined set of low frequencies.
[0075] In the DTMF detector 80 , the input signal 82 is simultaneously input into a high frequency detector 84 and a low frequency detector 86 . The high frequency detector 84 consists of a high frequency filter module 88 a that transmits the frequencies of the predetermined set of high frequencies and is preferably constructed essentially as described above in reference to the filter module 6 . The output of the filter module 88 a is input to an energy condition module 90 a which operates essentially as described above in reference to the energy condition module 10 . When the filtered signal satisfies the energy condition of the energy condition module, the filtered signal is analyzed by means of a high frequency detection module 92 a and a high frequency condition module 94 a, which operate as described above in reference to the frequency detection module 12 and the frequency condition module 16 , respectively. When the high frequency condition module 94 a detects one of the high frequencies, the detected high frequency is input to a DTMF detection module 96 . Otherwise, the high frequency condition module 94 a outputs an output of “n”.
[0076] The low frequency detector 84 consists of a low frequency filter module 88 b that transmits the frequencies of the predetermined set of low frequencies and is preferably constructed essentially as described above in reference to the filter module 6 . The output of the low frequency filter module 88 b is input to an energy condition module 90 b which operates essentially as described above in reference to the energy condition module 10 . When the filtered signal satisfies the energy condition of the energy condition module 90 b, the filtered signal is analyzed by means of a low frequency detection module 92 b and a low frequency condition module 94 b, which operate as described above in reference to the frequency detection module 12 and the frequency condition module 16 , respectively. When the low frequency condition module 94 b detects one of the low frequencies, the detected low frequency is input to a DTMF detection module 96 . Otherwise, the low frequency condition module 94 a outputs an output of “n”.
[0077] The DTMF detection module 96 thus receives inputs from the high frequency condition module 94 a and the low frequency condition module 94 b. The DTMF detection module detects pairs of simultaneously obtained inputs from the two frequency condition modules 94 a and 94 b indicating that one of the predetermined high frequencies was detected in the input signal 82 simultaneously with the detection of one of the predetermined low frequencies. The DTMF detection module 96 may further determine whether the detected pair of high and low frequencies satisfies any other predetermined requirements, especially requirements specified by a communications standard. When the DTMF detection module detects that a predetermined high frequency and a predetermined low frequency were simultaneously detected in the input signal 82 , and meet any predetermined requirements, the DTMF detection module outputs an output indicative of this.
|
The method provides a method and device for detecting in a single or multi frequency signal, one or more frequencies from a predetermined set of frequencies. The Signal is subjected to a complex filter substantially passing all of the frequencies in the predetermined set of frequencies. For each of one or more pairs of members of the complex filtered signal, a complex number Y d is determined having a phase indicative of a phase difference between the two members of the pair. The one or more frequencies are then determined based upon the one or more complex numbers. The method and device of the invention may be used in an apparatus such as a call indicator (CI) detector or a DTMF detector.
| 7
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This is a division of application Ser. No. 330,359 filed Feb. 7, 1973 now U.S. Pat. No. 3,888,840.
BACKGROUND OF THE INVENTION
1. field of Invention
This invention relates to novel α-hydrazinocarboxamide and α-(α '-acylhydrazino)carboxamide derivatives, to processes for their preparation and to their use as intermediates for the preparation of related derivatives.
2. Description of the Prior Art
Only within the last ten years has some attention been focused on α-hydrazinocarboxamides. This attention resulted from a chemical investigation by I. Ugi and F. Bodesheim, Justus Liebigs Ann. Chem., 666, 61 (1963). In this particular investigation α-(α ', β'-diacylhydrazino)carboxamides were prepared by the α-addition of acylhydrazones and carboxylic acids to isonitriles. The carboxamides of this latter study are readily distinguished from the compounds of the present invention by their lack of a basic nitrogen.
Indeed, the successful preparation of the present α-(hydrazino)- and α-(α'-acylhydrazino)caboxamides from hydrazones, acids and isonitriles is somewhat unexpected and surprising in light of a recent comment by Ugi. More explicitly, in "Newer Methods of Preparative Organic Chemistry", Vol. IV, N. Foerst, Ed., Academic Press, New York and London, 1968, p. 28, Ugi states that the lower basicity of the α-nitrogen in a hydrazone system has an adverse influence on α-additions involving hydrazones and it may be assumed that such reactions can rarely be used for preparative purposes.
SUMMARY OF THE INVENTION
The α-hydrazinocarboxamide derivatives of the present invention may be represented by Formula I, ##STR4## in which R 1 and R 2 each are lower alkyl or R 1 and R 2 together with the nitrogen atom to which they are joined form a piperidino or morpholino radical; R 3 is hydrogen, lower alkanoyl, benzoyl, p-nitrobenzoyl, p-aminobenzoyl, p-chlorobenzoyl, isocyanoacetyl, or protected amino acyl radicals, for example, N-formylglycyl or ##STR5## (N-carbobenzoxyglycylglycyl); R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is hydrogen or phenyl and R 8 is hydrogen or lower alkyl; R 5 is hydrogen or lower alkyl; or R 4 and R 5 together with the carbon atom to which they are joined form a cyclohexylidene radical; and R 6 is a cyclohexyl or CHR 9 COY wherein R 9 is hydrogen or benzyl and Y is hydroxyl, lower alkoxy or amino, with the provisos that when Y is hydroxyl then R 8 is hydrogen, that when Y is lower alkoxy then R 8 is lower alkyl and that when Y is amino R 4 is lower alkyl.
In one aspect of this invention the preparation of the compounds of formula I involve a key reaction wherein a hydrazone of formula II in which R 1 , R 2 and R 5 are as defined hereinbefore and R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is as defined hereinbefore and R 8 is lower alkyl or R 4 or R 5 together with the carbon atom to which they are joined form a cyclohexylidine radical, is treated with an acid of formula R 3 X in which R 3 is as defined hereinbefore and when R 3 is hydrogen, R 3 and X together represent an inorganic acid ionizable to provide a proton, and when R 3 is other than hydrogen as defined hereinbefore X represents a hydroxyl, in the presence of an isonitrile of formula R 6 NC in which R 6 is cyclohexyl or CHR 9 COY wherein R 9 is as defined hereinbefore and Y is lower alkoxy to obtain the corresponding compound of formula I ##STR6##
In another aspect of this invention compounds of formula I in which R 1 , R 2 , R 3 and R 5 are as defined in the first instance, R 4 is CHR 7 COOR 8 in which R 7 is as defined hereinbefore and R 8 is lower alkyl and R 6 is CH 2 COY in which Y is lower alkoxy are transformed to 2,5-dioxopyrrolidines of formula III either spontaneously during the formation of said latter compounds of formula I or by subjecting said latter compounds of formula I to alkaline conditions.
DETAILED DESCRIPTION OF THE INVENTION
The term "lower alkyl" as used herein contemplates straight chain alkyl radicals containing from one to six carbon atoms and branched chain alkyl radicals containing three to four carbon atoms and includes methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl and the like.
The term "lower alkanoyl" as used herein contemplates both straight and branched chain alkanoyl radicals containing from one to six carbon atoms and includes formyl, acetyl, propionyl, hexanoyl and the like.
The term "lower alkoxy" as used herein contemplates both straight and branched chain alkoxy radicals containing from one to six carbon atoms and includes methoxy, ethoxy, propoxy, hexyloxy and the like.
It will be noted that the structure of the compounds of this invention includes asymmetric carbon atoms. It is to be understood accordingly that the isomers arising from this asymmetry are included within the scope of this invention. Such isomers are obtained by classical separation techniques and by sterically-controlled synthesis.
The compounds of formula I of this invention exhibit utility as antibacterial agents against a number of microorganisms, for example, Pseudomonas aeruginosa, Proteus mirabilis, Proteus vulgaris, Klebsiella pneumoniae and Serratia marcescens, in standard tests for antibacterial activity, such as those described in "Antiseptics, Disinfectants, Fungicides and Sterilization", G. F. Reddish, Ed., 2nd ed., Lea and Febiger, Philadelphia, 1957 or by D. C. Grove and W. A. Randall in "Assay Methods of Antibiotics", Med. Encyl. Inc., New York 1955.
For example, a test like the serial broth dilution, see Grove and Randall, cited above, in which dilutions of the compounds of this invention in nutrient broth are inoculated with the mircroorganisms or fungi, described above, incubated at 37° C. for 2 days, respectively, and examined for the presence of growth, shows that 3-[N-(dimethylamino)formamido]-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester (Example 27) is able to inhibit growth totally in this system of Proteus vulgaris, Klebsiella pneumoniae and Serratia marcescens at a concentration of 100 mcg/ml. or less.
When the compounds of formula 1 are employed as antibiotic or antifungal agents in warm-blooded animals, e.g. rats, they may be administered alone or in combination with pharmacologically acceptable carriers. The proportion of the compound is determined by the solubility and chemical nature of the compound, chosen route of administration and standard biological practice. For example, they may be administered orally in solid form containing such excipients as starch, milk sugar, certain types of clay and so forth. They may also be administered orally in the form of solutions or they may be injected parenterally. For parenteral administration they may be used in the form of a sterile solution containing other solutes, for example, enough saline or glucose to make the solution isotonic.
The dosage of the present compounds as antibiotic agents will vary with the form of administration and the particular compound chosen. Furthermore, it will vary with the particular compounds chosen. Furthermore, it will vary with the particular host under treatment. Generally, treatment is initiated with small dosages substantially less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. In general, the compounds of this invention are most desirably administered at a concentration level that will generally afford antibacterially or antifungally effective results without causing any harmful or deleterious side effects and preferably at a level that is in a range of from about 1.0 mg to about 1000 mg. per kilo per day, although as aforementioned variations will occur. However, a dosage level that is in the range of from about 10 mg to about 500 mg per kilo per day is most desirably employed in order to achieve effective results.
In addition, the said ultimate products may be employed topically. For topical application they may be formulated in the form of solutions, creams, or lotions in pharmaceutically acceptable vehicles containing 0.1-5 per cent, preferably 2 per cent, of the agent and may be administered topically to the infected area of the skin.
Also the antibacterial properties of the said ultimate products may be utilized for washing equipment in hospitals, homes and farms, instruments used in medicine and bacteriology, clothing used in bacteriological laboratories, and floors, walls and ceilings in rooms in which a background free of gram-positive and gram-negative microorganisms, such as those listed above, is desired. When employed in this manner the said ultimate products are formulated in a number of compositions comprising the active compound and an inert material. In such compositions, while the said ultimate products may be employed in concentrations as low as 500 p.p.m., from a practical point of view, it is desirable to use from about 0.1% to about 5% by weight or more.
The formulations that may be used to prepare antiseptic wash solutions of the compounds of this invention are varied and may readily be accomplished by standard techniques, see for example, "Remington's Practice of Pharmacy", E. W. Martin et al., Eds., 12th ed., Mack Publishing Company, Easton, Penn., 1961, pp. 1121-1150. In general, the said ultimate products are made up in stock solutions. They can also be formulated as suspensions in an aqueous vehicle. These make useful mixtures for decontaminating premises. Also, aqueous vehicles containing emulsifying agents, such as sodium lauryl sulfate, and relatively high concentrations, e.g., up to about 5% by weight, of the compounds may be formulated by conventional techniques.
A typical antiseptic preparation useful for disinfecting floors, walls, ceiling, and articles in a contaminated room may be prepared by adding 5 to 25 g. of 3-[N-(dimethylamino)formamido]-3-methyl-2,5-dioxo-1-pyrrolidine-acetic acid ethyl ester to a mixture of 150 to 300 g of polyethylene glycol 1540 and 150 to 300 g of polyethylene glycol 300. The resulting mixture is stirred while a solution of 1 to 10 g of sodium lauryl sulfate in 300 to 400 ml of water is added portionwise. The article to be disinfected is coated or immersed in the preparation for a prolonged time, for example, one hour, and then rinsed with sterile water.
In addition, the compounds of formula I exhibit trichomonacidal activity against certain Trichomonas species, for example, Trichomonas vaginalis. A demonstration of this activity is readily achieved in standard tests for trichomonacidal activity; for example, see R. J. Schnitzer in "Experimental Chemotherapy", Vol. 1, R. J. Schnitzer and F. Hawking, Ed., Academic Press, New York, 1963, p. 289.
When the compounds of formula I are employed as trichomonacidal agents they may be administered in the same manner described above for their application as antibacterial agents.
Likewise, the 2,5-dioxopyrrolidines of formula III exhibit a similar degree of the antibacterial and trichomonacidal activities, described above. Accordingly, they may be used for this purpose in the same manner as described for the compounds of formula I.
In practising the process of this invention three classes of starting material are required; namely, hydrazones of formula II, acids of formula R 3 X and isonitriles of formula R 6 NC.
The requisite hydrazones of formula 11 are prepared by condensing an appropriately substituted hydrazine of formula R 1 R 2 NNH 2 in which R 1 and R 2 are as defined in the first instance, with a carbonyl compound of formula R 4 R 5 CO in which R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is hydrogen or phenyl and R 8 is lower alkyl and R 5 or R 4 and R 5 together are as defined hereinbefore.
Hydrazines of formula R 1 R 2 NNH 2 are either known for example, 1,1-dimethyl hydrazine, N-aminopiperidine, N-aminomorpholine, or they are prepared by known methods; for example, see E. Muller in "Methoden der Organischen Chemie", Houben-Weyl, E. Muller, Ed., Vol. 10/2, Georg Thieme Verlag, Stuttgard, 1967, p. 50.
Likewise, the carbonyl compounds of formula R 4 R 5 CO are known and most are commercially available, for example, ethyl acetoacetate, isobutyraldehyde and cyclohexanone, or are prepared by known methods; for example, see P. Karrer, "Organic Chemistry", 2nd ed., Elsevier Publishing Co., Inc., New York, 1946, p. 149.
The condensation of the hydrazine of formula R 1 R 2 NNH 2 and the carbonyl compound of formula R 4 R 5 CO is preferably carried out in an inert solvent at an elevated temperature, at or near the reflux temperature of the mixture. Either an anhydrous, water-immiscible hydrocarbon solvent, for example, benzene or toluene, with concomitant physical removal of water as it is being formed, e.g. by means of a Dean-Stark water separator, or a lower alkanol solvent, for example, ethanol, propanol or isopropanol may be employed. Thereafter, evaporation of the solvent and purification of the residue, for example, by distillation or crystallization, yields the corresponding hydrazone of formula II.
The acids of formula R 3 X are known and are commercially available and include the inorganic acids, hydrochloric, sulfuric, phosphoric, hydrobromic acid and the like, or the organic acids, formic, acetic, benzoic, p-nitrobenzoic and the like.
The requisite isonitriles of formula R 6 NC also are known, for example, cyclohexyl isonitrile [(I. Ugi and R. Meyr, Ber., 93, 239 (1960)] and ethyl isocyanoacetate [R. Appel et al., Angew. Chem., Int. ed., 10, 132 (1971)], or are easily prepared by known methods, for example, see P. Hoffmann, et al., in "Isonitrile Chemistry", Organic Chemistry, Vol. 20, I. Ugi, Ed., Academic Press, New York, 1971, p. 9.
Next, in a key reaction of the process of this invention, the aforementioned hydrazone of formula 11 is condensed with the acid of formula R 3 X, and the isonitrile of formula R 6 NC, described above, to yield the corresponding compounds of formula I.
Although not critical it is preferable to use approximately equimolar amounts of the three requisite starting materials, for this condensation. The condensation is effected most conveniently in an inert solvent, for example, halogenated hydrocarbons including methylene dichloride, chloroform, and carbon tetrachloride, ethers and cyclic ethers including dioxane, diethyl ether and tetrahydrofuran, or lower aliphatic alcohols including methanol, ethanol and propanol. However, when the three starting materials are mutually soluble or the mixture thereof becomes liquid during the course of the condensation the solvent may be omitted without any deleterious effects.
The temperature and duration of the condensation also are not critical. The reaction may be performed at temperatures ranging from -20° to 100° C.; however, a range from 10° to 40° C is most convenient, with room temperature to the boiling point of the solvent employed being preferred. The reaction time varies widely and depends on the reactivity of the various starting materials; however, reaction times from 15 minutes to several days are employed generally, with six hours to two days being preferred.
Thereafter the product is isolated and purified according to standard procedures. For instance the product is extracted with a water-immiscible solvent and, if needed, purified by chromatography and crystallization.
In this manner there are obtained the compounds of formula I in which R 1 , R 2 , R 3 and R 5 are defined in the first instance, R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CHCOOR 8 wherein R 7 is hydrogen or phenyl and R 8 are lower alkyl or R 4 and R 5 together with the carbon atom to which they are joined form a cyclohexylidene radical, and R 6 is cyclohexyl or CHR 9 COY in which R 9 is as defined hereinbefore and Y is lower alkoxy.
As noted hereinbefore the compounds of formula I in which R 1 , R 2 , R 3 and R 5 are as defined in the first instance, R 4 is CHR 7 COOR 8 in which R 7 is as defined hereinbefore and R 8 is lower alkyl and R 6 is CHR 9 COY in which R 9 is hydrogen and Y is lower alkoxy are transformed to the corresponding 2,5-dioxopyrrolidines of formula III. This transformation takes place spontaneously to some extent (10-80%) during the course of the condensation of the hydrazone of formula R 1 R 2 NN = C(R 5 )CH 2 COOR 8 in which R 1 , R 2 and R 5 are as defined herein and R 8 is lower alkyl, with a lower alkyl ester of isocyanoacetic acid and an acid of formula R 3 X as defined herein under the conditions described above for such condensations. The mixture of the corresponding products of formulae I and III obtained under these conditions may be separated by crystallization or chromotagraphy on silica gel. If desired, the mixture is readily converted totally to the corresponding compound of formula III by treating the mixture with a base, for example, the alkali metal carbonates including sodium or potassium carbonate or the alkali metal hydroxides including sodium or potassium hydroxide in an inert solvent, for example, chloroform, benzene, tetrahydrofuran or ethanol. Completion of this conversion under alkaline conditions is achieved usually at temperatures ranging from 20° to 100° C, preferably 50° to 60° C., and reaction times of from 10 minutes to 6 hours, preferably one to two hours.
The compounds of formula I in which R 4 is CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is as defined hereinbefore and R 8 is hydrogen and R 6 is CHR 9 COY in which R 9 is as defined hereinbefore and Y is hydroxyl, mainly, the corresponding acid derivatives of the aforementioned esters, are obtained by treatment of said corresponding esters with a hydrolyzing agent. Generally speaking, this conversion is most conveniently performed by employing a base as the hydrolyzing agent, although hydrolysis under acidic conditions is also applicable. It should be noted herein that when compounds of formula 1 in which R 4 is CHR 7 COOR 8 in which R 8 is lower alkyl and R 6 is CH 9 COY in which Y is lower alkoxy are subjected to the above hydrolyzing conditions a mixture of the corresponding diacid and 2,5-dioxopyrrolidine of formula III results.
For basic hydrolysis a preferred embodiment involves subjecting the lower alkyl ester to the action of a strong base, for example, sodium or potassium hydroxide, in the presence of sufficient water to effect hydrolysis of the ester. The hydrolysis is performed using a suitable solvent, for example, methanol or ethanol.
The reaction mixture is maintained at a temperature of from 0° C to the reflux temperature until hydrolysis occurs. Usually from 10 minutes to six hours is sufficient for this hydrolysis. The reaction mixture is then rendered acidic with an acid, for example, acetic acid, hydrochloric acid, sulfuric acid and the like, to obtain the corresponding free acid.
The compounds of formula 1 in which R 4 is lower alkyl and R 6 is CHR 9 COY in which R 9 is as defined hereinbefore and Y is amino are obtained by treatment of the corresponding lower alkyl esters, described above, with ammonia according to standard amidation methods. Preferred conditions for this amidation include treatment of the appropriate ester of formula 1 with a saturated solution of ammonia in an inert solvent, for example, methanol, ether or tetrahydrofuran at 0° to 20° C for 6 hours to 5 days.
The compounds of formula I in which R 3 is p-aminobenzoyl are obtained by treating the corresponding compounds of formula I, described above, in which R 3 is p-nitrobenzoyl with a reducing agent. In this case the use of hydrogen in the presence of a noble metal catalyst, for example, palladium, platinum and the like in a hydrogenation apparatus is a preferred and convenient method.
Finally, the compounds of formula I in which R 3 is isocyanoacetyl (COCH 2 NC) are prepared directly from the aforementioned, corresponding compounds of formula I in which R 3 is N-formylglycyl. This transformation is effected readily with dehydrating agents known to be effective for transforming known formamides to corresponding isonitriles, see P. Hoffmann, et al., cited above. A preferred method in this case is the use of phosgene in the presence of triethylamine.
The following examples illustate further this invention.
EXAMPLE 1
Ethyl Levulinate Dimethyl Hydrazone
A mixture of 21.5 g (0.15 mole) of ethyl levulinate and 15.0 g (0.25 mole) of anhydrous dimethylhydrazine in 35 ml of ethanol is heated at reflux for 4 hours. The solvent is removed and the residue fractionally distilled. The title compound is collected, b.p. 98°-100° C/15 mm., nmr (CDCl 3 δ 1.25 (t, J=7,3H), 1.95 (3H), 2.40 (6H), 2.53 (4H), 4.13 (q, J=7,2H).
In the same manner but replacing ethyl levulinate with an equivalent amount of ethyl acetoacetate, ethyl acetoacetate dimethyl hydrazone, b.p. 88°-92° C/ 19-20 mm, ν max CHCl .spsb.3 3245, 3180 and 1728 cm -1 , is obtained.
Similar replacement of the ethyl levulinate with ethyl α-phenylacetoacetate gives ethyl α-phenylacetoacetate dimethyl hydrazone, b.p. 138°-143° C/5 mm, nmr (CDCl 3 ) δ 1.13 and 1.30 (2t, J = 7, 3H), 1.47 (3H), 1.56(3H), 1.86 (3H).
Similar replacement of the ethyl levulinate with cyclohexanone gives cyclohexanone dimethyl hydrazone, b.p. 80°-82° C/25 mm, nmr (CDCl 3 ) δ 1.66 (6H), 2.43 (10H).
Similar replacement of the ethyl levulinate with 2-oxocyclohexanecarboxylic acid ethyl ester gives 2-oxocyclohexanecarboxylic acid ethyl ester dimethyl hydrazone, b.p.132° C/11mm.
EXAMPLE 2
3-(Piperidinoimono)butyric Acid Methyl Ester
A mixture of methyl acetoacetate (13 g. 0.10 mole) and 1-aminopiperidine (15 g, 0.15 mole) in absolute ethanol (30 ml) is heated at reflux for 4 hr. The solvent is removed and the residue fractionally distilled. The title compound has b.p. 125°-126° C/13 mm.
In the same manner but replacing 1-aminopiperidine with an equivalent amount of 1-aminomorpholine, 3-(morpholinoimino)butyric acid ethyl ester, b.p. 150°-152° C/20 mm, ν max CHCl .spsb.3 3240, 3180, 1720, 1640, 1600 cm - 1 , is obtained.
In the same manner but replacing ethyl acetoacetate with an equivalent amount of cyclohexanone, 1-(cyclohexylideneamino)piperidine, b.p. 124°-217° C/15-18 mm, is obtained. Reported b.p. for this compound is 76° C/0.4 mm, H. Boehlke and W. Kliegel, Arch. Pharm. 229, 245 (1966).
EXAMPLE 3
Isobutyraldehyde Dimethyl Hydrazone
A solution of isobutyraldehyde (43 g. 0.6 mole) and dimethylhydrazine (60 g, 1.0 mole) in benzene (500 ml) is heated at reflux temperature for 5 hr. using a Dean-Stark apparatus to collect the water. The solution is evaporated and the residue fractionally distilled. The hydrazone is obtained as a yellow oil, b.p. 120° C, ν max Film 1610, 1475, 1450 cm -1 .
In the same manner but replacing isobutyraldehyde with an equivalent amount of isovaleraldehyde, isovaleraldehyde dimethyl hydrazone, b.p. 145° -149° C is obtained.
Similar replacement of the isobutyraldehyde with an equivalent amount of propionaldehyde or hexaldehyde gives propionaldehyde dimethyl hydrazone and hexaldehyde dimethyl hydrazone, respectively.
EXAMPLE 4
2-Isocyano-3-phenylpropionic Acid Methyl Ester
A solution of phosgene (5.2 g, 0.052 mole) in dry methylene chloride (45 ml) is added dropwise to a stirred solution of N-formylphenylalanine methyl ester (10.0 g, 0.048 mole) and 1-methylmorpholine (13 g, 0.125 mole) in dry methylene chloride (25 ml) at -30° C. After completion of the addition the filtrate is concentrated under reduced pressure at room temperature. Benzene is added to the residue followed by filtration and concentration of the resulting solution. The residue is distilled to afford the title compound as a yellow oil, b.p. 97° C/0.3 mm, ν max CHCl .spsb.3 2150, 1746, 1595, 1578, 1489, 694 cm -1 .
The starting material, N-formylphenylalanine methyl ester, is known; see R.G. Jones, J. Amer. Chem. Soc., 71, 644 (1949) for D L-form and F. Bergel, et al., J. Chem. Soc., 3802 (1962) for L-form.
In the same manner but replacing the preceding starting material with an equivalent amount of N-formylmethionine ethyl ester, described in German Pat. No. 1,201,357, issued September 23, 1965 [Chem. Abstr. 63, 18260 (1965)], 2-isocyano-4-methylthiobutyric acid ethyl ester, b.p. 77°-79° C/ 0.1 mm, is obtained.
EXAMPLE 5
N-cyclohexyl-3-(dimethylaminoformamido)-3-methylglutaramic Acid Ethyl Ester (1; R 1 and R 2 = CH 3 , R 3 = CHO, R 4 = CH 2 CH 2 COOC 2 H 5 , R 5 = CH 3 and R 6 = cyclohexyl)
A solution of the hydrazone of formula II, ethyl levulinate dimethyl hydrazone (9.39 g, 0.05 mole), described in Example 1, and the isonitrile of formula R 6 NC, cyclohexyl isonitrile (5.45 g, 0.05 mole), in 10 ml of dry methylene dichloride is cooled in an ice bath and treated dropwise with the acid of formula R 3 X, formic acid (2.35 g, 0.05 mole). The mixture is stirred for 20 minutes in the cold and then stirred at room temperature until completion of the condensation. [In this case the condensation is complete after 3 hr. as determined by thin layer chromatography (tlc) using silica gel plates and a solvent system consisting of benzene-ethyl acetate (1:1)]. The reaction mixture is diluted with 4N sodium hydroxide and extracted with ethyl acetate. The extract is washed with water until neutral, dried (MgSO 4 ) and evaporated yielding a solid residue. The residue is crystallized from methylene dichloride-hexane to yield the title compound, m.p. 81.5°-83° C., ν max CHCl .spsb.3 3455, 3340, 1727, 1507 cm -1 .
EXAMPLE 6
N-{[N-(Dimethylamino)-N-(N-formylglycyl)]-Dl-valyl}glycine Ethyl Ester (1; R 1 B. A. R 2 = CH 3 ; R 3 = COCH 2 NHCHO, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOC 2 H 5 )
The acid of formula R 3 X,N-formylglycine (15.4 g), described by R. S. Tipson and B. A. Pawson, J. Org. Chem., 26, 4698 (1961), is added dropwise to a solution of the hydrazone of formula 11, isobutyraldehyde dimethyl hydrazone (17.1 g), described in Example 3, and the isonitrile of formula R 6 NC, ethyl isocyanoacetate (16.0 g), in 50 ml of anhydrous methanol containing 20 g. of hydrated alkali-aluminum silicate (Molecular Sieves No. 4), cooled to 0° C. The mixture is stirred at room temperature until completion of the condensation. [In this case the condensation is complete after 24 hr. as determined by tlc using silica gel plates and a solvent system consisting of ethyl acetate-methanol (9:1)]. The mixture is filtered and concentrated. The residue is subjected to chromatography on silica gel. Elution with ethyl acetate-methanol (9:1) gives the title compound, nmr (CDCl 3 ) δ 0.91 and 1.02 (2d, J=6.5, 6H), 1.27 (t, J=7, 3 H), 2,53 (3H), 2.56 (3H), 3.03 (m, 1H), 3.44 (d, J = 11, 1H), 3.97 (2H), 4.20 (q, J = 7, 2H), 4.35 (2H), 6.62 (1H).
EXAMPLE 7
N-[(N-Dimethylamino)-DL-valyl]glycine Ethyl Ester (1, R 1 and R 2 = CH 3 , R 3 = H,R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOC 2 H 5 )
A solution of the hydrazone of formula 11, isobutyraldehyde dimethylhydrazone (19.6 g, 0.172 mole) described in Example 3, water (17.2 ml), and methanol (28.6 ml) is stirred at ice-bath temperature. After 5 min., 12N HCl (14.5 ml) is added slowly. After an additional 2 min. the isonitrile, ethyl isocyanoacetate (19.4 g, 0.172 mol) is added. The solution is stirred at room temperature for 1.5 hr. The solution is diluted with methylene chloride (500 ml), and washed with 4N NH 4 OH (100 ml), water (50 ml), and a saturated solution of sodium chloride (100 ml). The organic phase is dried (Na 2 SO 4 ) and concentrated. The orange oil is distilled to yield the title compound, b.p. 124° C/0.1 mm, ν max CHCl .spsb.3 3380, 1730, 1660, 1510 cm -1 .
By following the procedure of Example 5, 6 or 7 and using the appropriate hydrazone of formula 11, acid of formula R 3 X and isonitrile of formula R 6 NC then other compounds of formula II are obtained. Examples of such compounds of formula I are listed in Table I together with the hydrazone, acid and isonitrile required for their preparation.
TABLE 1__________________________________________________________________________Hydrazone Acid of Isonitrile Product ofEx. of Formula 11 Formula R.sup.3 X (R.sup.6 NC) Formula 1__________________________________________________________________________8 ethyl aceto- formic acid cyclohexyl N-cyclohexyl-3-(dimethyl-acetate di- isonitrile aminoformamido)-3-methyl hydra- methylsuccinamic acidzone ethyl ester, m.p. 79.5 - 81° C, ν.sub.max CHCl.sub.3 1728, 1668 cm.sup.-.sup.1.9 ethyl levuli- benzoic acid cyclohexyl N-cyclohexyl-4-[N-(di-nate dimethyl isonitrile methylamino)benzamido]-hydrazone 4-methylglutaramic acid ethyl ester, m.p. 79 - 80.5° C, ν.sub.max CHCl.sub.3 1728, 1665, 1650 cm.sup.-.sup.1.10 ethyl aceto- formic acid 2-isocyano-3- N-(α-carboxyphenethyl)-acetate di- phenylpro- 3-[N-(dimethylamino)-methyl hydra- pionic acid formamido]-3-methyl-zone methyl ester succinamic acid ethyl (described in N-methyl diester, m.p. Example 4) 91 - 109° C, nmr (CDCl.sub.3) δ 1.24 (+, J=7,3H), 2.78 (6H), 2.82 (m,2H), 3.17 (d, J=6.5, 2H)11 isobutyral- formic acid 2-isocyano-3- N-[N-(dimethylamino)-N-dehyde di- phenylpro- formyl-DL-valyl]phenyl-methyl hydra- pionic acid alanine methyl ester,zone methyl ester ν.sub.max CHCl.sub.3 1735, 1640-1660cm.sup.-.sup.112 cyclohexanone formic acid 2-isocyano-3- N-{1-[N-(dimethylamino)-dimethyl hydra- phenylpro- formamido]cyclohexyl-zone pionic acid carbonyl}phenylalanine methyl ester methyl ester, m.p. 80 - 83° C13 cyclohexanone p-nitroben- 2-isocyano-3- N-{1-[N-(dimethylamino)-dimethyl zoic acid phenylpro- p-nitrobenzamido]cyclo-hydrazone pionic acid hexylcarbonyl}phenyl- methyl ester alanine methyl ester, m.p. 116 - 117° C14 isobutyralde- formic acid ethyl isocy- N-[N-(dimethylamino)-N-hyde dimethyl anoacetate formyl -DL-valyl]glycinehydrazone ethyl ester, b.p. 150 - 153° C/0.1 mm, ν.sub.max Film 3300, 1745, 1670 cm.sup.-.sup.1.15 cyclohexanone formic acid ethyl iso- N-{1-[N-(dimethylamino)-dimethyl cyanoacetate formamido]cyclohexyl-hydrazone carbonyl}ethyl - ester, m.p. 87 - 89° C ν.sub.max CHCl.sub.3 1732, 1658 cm.sup.-.sup.1.16 cyclohexanone N-carbobenzoxy- ethyl iso- N-[1-{1-[N-(carboxy-dimethyl glycylglycine cyanoacetate glycyl)glycyl]-2,2-di-hydrazone methylhydrazino}cyclo- hexylcarbonyl]glycine N-benzyl ethyl diester m.p. 138 - 139° C, ν.sub.max CHCl.sub.3 1720, 1655 cm.sup.-.sup.1.17 cyclohexanone benzoic acid ethyl iso- N-{1-[N-(dimethylamino)-dimethyl cyanoacetate benzamido]cyclohexyl-hydrazone carbonyl}glycine ethyl ester, m.p. 90 - 92° C, ν.sub.max CHCl.sub.3 1730, 1660, 1630 cm.sup.-.sup.1.18 cyclohexanone p-nitro- ethyl iso- N-{1-[N-(dimethylamino)-dimethyl benzoic acid cyanoacetate p-nitrobenzamido]cyclo-hydrazone hexylcarbonyl}glycine methyl ester, m.p. 86 - 88° C, ν.sub.max CHCl.sub.3 1730, 1660, 1640 cm.sup.- .sup.1.19 ethyl aceto- p-nitro- ethyl iso- N-(carboxymethyl)-3-acetate di- benzoic acid cyanoacetate [N-(dimethylamino)-p-methyl hydra- nitrobenzamido]-3-zone methylsuccinamic acid diethyl ester, m.p. 90 - 94° C, ν.sub.max CHCl.sub.3 1725, 1665 cm.sup.-.sup.1.20 cyclohexanone formic acid 2-isocyano-3- N-{1-[N-(dimethylamino)-dimethyl phenylpro- formamido]cyclohexyl-hydrazone pionic acid carbonyl}-DL-phenylala- - methyl ester nine methyl ester, m.p. 84-86° C, ν.sub.max CHCl.sub.3 1735, 1660 cm.sup.-.sup.1.21 isobutyralde- ±-butoxy- 2-isocyano-4- N-{N-[N-(carboxyglycyl)-hyde dimethyl carbonyl- methylthio- N-(dimethylamino-DL-valyl]}- hydrazone gly cine butyric acid DL-methionine N-±-butyl ethyl ester ethyl diester, nmr (CDCl.sub.3) (described in δ 0.90 (d, J=7,3H), 1.05 Example 4) (d, J=7,3H), 1.30 (2×t, J=7,3H), 2.10 (2×s,3H), 2.56 (2×s, 6H)22 isobutyral- formic acid 2-isocyano-4- N-[N-(dimethylamino)-N-dehyde dimeth- methylthio- formyl-DL-valyl]-DL-yl hydrazone butyric acid methionine ethyl ester, ethyl ester nmr (CDCl.sub.3) δ 0.95 N-{N-[- J=6.5,3H), 1.03 (d, J=6.5, }glycine 3H), 1.26 (+, J=7,3H). 2.10 (3H), 2.58 (6H)23 isovaleral- ±-butoxy- 2-isocyano-4- N-{N-[N-(carboxyglycyl)-dehyde di- carbonylgly- methylthio- N-(dimethylamino)-DL-methyl hydra- cine butyric acid leucyl]}-DL-methioninezone ethyl ester N-±-butyl ethyl diester, nmr (CDCl.sub.3 δ 0.98 (d, J=5,6H), 1.26 (2+, J=7, 3H), 1.46(9H), 2.11(2s, 3H), 2.56(6H)24 1-(cyclo- formic acid ethyl isocy- N-[1-(N-piperidinoform-hexylidene- anoacetate amido)cyclohexylcarbon-amino)piperi- yl]glycine ethyl ester,dine m.p. 119 - 120° C, ν.sub.max CHCl.sub.3 1730, 1655 cm.sup.-.sup.1.25 1-(cyclohex- p-nitro- ethyl iso-ylidene- benzoic acid cyanoacetate N-{1-[(p-nitro-N-piperid-amino)piperi- ino)benzamido]cyclohexyl-dine carbonyl}glycine ethyl ester, m.p. 133 - 135° C, ν.sub.max CHCl.sub.3 1730, 166026 isobutyral- cm.sup.-.sup.1. ±-butoxy- ethyl, so- N-{N-[N-(carboxyphenyl-dehyde dimeth- carbonyl- cyanoacetate alanyl)-N-(dimethyl-yl hydrazone phenylal- amino)-DL-valyl]}glycine anine N-±-butyl ethyl diester, separable into two isomers by chromatography (SiO.sub.2), isomer A: [α].sub.D.sup .25 = -66.9° (CHCl.sub.3), nmr (CDCl.sub.3) δ 0.91 & 1.04 (6H), 1.29 (3H); Isomer B: [α].sub.D.sup.24 = +40.0° (CHCl.sub.3), nmr (CDCl.sub.3) δ 0.75 & 1.03 (6H), 1.28 (3H).__________________________________________________________________________
EXAMPLE 27
3-[N-(Dimethylamino)formamido]-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester (III; and R 1 and R 2 = CH 3 , R 3 = CHO, R 5 =CH 3 and R 7 = H)
A solution of the hydrazone of formula II, ethyl acetoacetate dimethylhydrazone (13.7g., 0.08 mole), the acid of formula R 3 X, formic acid (3.1 ml, 0.08 mole) and the isonitrile of formula R 6 NC, ethyl isocyanoacetate (9.1 g, 0.08 mole) in dry methylene chloride (25 ml) is stirred at room temperature until completion of the reaction. [In this case the reaction is complete after 21 hr. as determined by tlc using silica gel plates and a solvent system of benzeneethyl acetate (1:1)]. The mixture is diluted with ethyl acetate (200 ml) and 4N NH 4 OH (100 ml). The organic layer is separated, washed with water, dried (MgSO 4 ) and concentrated under reduced pressure. The oily residue is crystallized from hexane-methylene chloride to give the title compound, m.p. 89° - 92° C., ν max CHCl .spsb.3 1785, 1740, 1715, 1665 cm - 1 .
EXAMPLE 28
3-(p-Chloro-N-piperidinobenzamido)-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester (III; R 1 and R 2 = (CH 2 ) 5 , R 3 = p-chlorophenyl, R 5 =CH 3 and R 7 = H)
A solution of the hydrazone of formula II, ethyl acetoacetate piperidinehydrazone (21.2 g, 0.1 mole), ethyl isocyanoacetate (11.3 g, 0.1 mole) and p-chlorobenzoic acid (15.6 g, 0.1 mole) in dry methylene chloride (50 ml) are stirred at reflux temperature for 7 days. The solution is diluted with methylene chloride (50 ml), and washed with 0.5 N ammonium hydroxide (50 ml), water (50 ml), and saturated sodium chloride solution (50 ml). The organic phase is dried (Na 2 SO 4 ) and concentrated. The resulting oil and anhydrous potassium carbonate (20 g) in chloroform (200 ml) is heated at reflux temperature for 4 hr. The solution is filtered and the filtrate poured onto a column of silica gel (400 g). Elution with ethyl acetate-chloroform (1:3) affords the title compound having m.p. 153° - 155° C. after recrystallization from methylene chloride-hexane.
EXAMPLE 29
3-(2,2-Dimethylhydrazino)-3-methyl-2,3-dioxo-4-phenyl-1-pyrrolidineacetic acid ethyl ester III; R 1 and R 2 = CH 3 , R 3 = H, R 5 = CH 3 and R 7 = phenyl)
By following the procedure of Example 7 but replacing isobutyraldehyde dimethylhydrazone with an equivalent amount of ethyl-α-phenylacetoacetate dimethylhydrazone, described in Example I, then the title compound, m.p. 108° - 109° C., ν max CHCl .spsb.3 1770, 1738, 1700 cm -1 , is obtained.
By following the procedures of Example 27, 28 or 29 and using the appropriate hydrazone of formula II, acid of formula R 3 X and isonitrile of formula R 6 NC then other compounds of formula III are obtained. Examples of such compounds of formula III are listed in Table II together with the hydrazone, acid and isonitrile required for their preparation.
TABLE II__________________________________________________________________________ Hydrazone Acid of Isonitrile Product ofEx. of Formula II Formula R.sup.3 X (R.sup.6 NC) Formula III__________________________________________________________________________30 ethyl aceto- acetic acid ethyl iso- 3-[N-(dimethylamino)- acetate di- cyanoacetate acetamido]-3-methyl-2,5- methyl hydra- dioxo-1-pyrrolidine- zone acetic acid ethyl ester m.p. 112 - 115° C.31 ethyl aceto- benzoic acid ethyl iso- 3-[N-(dimethylamino)- acetate di- cyanoacetate benzamido]-3-methyl-2,5- methyl hydra- dioxo-1-pyrrolidine- zone acetic acid ethyl ester, m.p. 100 - 102° C.32 ethyl aceto- p-nitro- ethyl iso- 3-[N-(dimethylamino)- acetate di- benzoic acid cyanoacetate p-nitrobenzamido ]-3- methyl hydra- methyl-2,5-dioxo-1- zone pyrrolidineacetic acid ethyl ester, m.p. 179 - 182° C.33 ethyl aceto- p-chloroben- ethyl iso- 3-[p-chloro-N-(dimethyl- acetate di- zoic acid cyanoacetate amino)benzamido]-3-methyl- methyl hydra- 2,5-dioxo-1-pyrrolidine- zone acetic acid ethyl ester, m.p. 123 - 125° C.34 3-(piperi- formic acid ethyl iso- 3-methyl-2,5-dioxo-3-(N- dinoimino)- cyanoacetate piperidinoformamido)-1- butyric acid pyrrolidineacetic acid methyl ester ethyl ester, m.p. 89 - (described in 92° C. Example 2)35 3-(piperi- benzoic acid ethyl iso- 3-methyl-2,5-dioxo-3-(N- dinoimino)- cyanoacetate piperidinobenzamido)-1- butyric acid pyrrolidineacetic acid methyl ester ethyl ester, m.p. 140 - 144° C.36 3-(piperi- p-nitroben- ethyl iso- 3-methyl-3-[p-nitro-N- dinoimino)- zoic acid cyanoacetate piperidino)benzamido]- butyric acid 2,5-dioxo-1-pyrrolid- methyl ester ineacetic acid ethyl ester, m.p. 232 - 235° C.37 3-(morpholino- formic acid ethyl iso- 3-methyl-3-(N-morpho- imino)butyric cyanoacetate linoformamido)-2,5-dioxo- acid methyl 1-pyrrolidineacetic acid ester (des- ethyl ester, m.p. 148 - cribed in 149° C. Example 2)38 3-(morpholino- p-nitroben- ethyl iso- 3-[p-nitro-N-(morpho- imino)butyric zoic acid cyanoacetate lino)benzamido]-3-methyl- acid methyl 2,5-dioxo-1-pyrrolidine- ester acetic acid ethyl ester, (described in m.p. 237 - 238° C. Example 2)39 ethyl α-phenyl formic acid ethyl iso- 3-[N-(dimethylamino)- acetoacetate cyanoacetate formamido]-3-methyl-2,5- dimethyl dioxo-4-phenyl-1- hydrazone pyrrolidineacetic acid ethyl ester, m.p. 123 - 124° C.__________________________________________________________________________
EXAMPLE 40
3-[N-(Dimethylamino)-p-nitrobenzamido]-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester III; R 1 and R 2 = CH 3 , R 3 = p-nitrophenyl, R 5 = CH 3 and R 7 H)
A solution of the compound of formula I, N-(carboxymethyl)-3-[N-dimethylamino)-p-nitrobenzamido]-3-methylsuccinamic acid diethyl ester (15.74 g, 0.035 mole), described in Example 19, and anhydrous potassium carbonate (15.0 g) in chloroform (100 ml) is heated at reflux for 90 min. After filtering the mixture the filtrate is concentrated. The residue is recrystallized from ethyl acetate to afford the title compound, identical to the product of Example 32.
The title compound is also obtained according to the procedure of this example in which the potassium carbonate is replaced by an equivalent amount of sodium carbonate or sodium or potassium hydroxide.
By following the procedure of this example and using the appropriately substituted compound of formula I in which R 4 represents CHR 7 COO-(lower alkyl) and R 6 represents CH 2 C00-(lower alkyl) then the corresponding compounds of formula III, for example, those described in Examples 27 to 39, are obtained.
EXAMPLE 41
N-Cyclohexyl-4-(dimethylaminoformamido)-4-methylglutaramic acid (I; R 1 and R 2 = CH 3 , R 3 = CHO, R 4 = CH 2 CH 2 COOH, R 5 = CH 3 and R 6 = cyclohexyl)
To 5.10 g (0.015 moles) of the corresponding ethyl ester of the title compound, described in Example 5 in 50 ml. of dry methanol, a solution of 1.68 g (0.030 moles) of potassium hydroxide in 5 ml. of dry methanol is added. The mixture is stirred for 6 hr. at room temperature. The mixture is concentrated under reduced pressure, cooled and rendered acidic (pH = 4) with dil. HCl. The resulting gum is taken up in chloroform. The chloroform extract is washed with water, dried (MgSO 4 ), and concentrated. The residue is crystallized from methylene chloride-ether to afford the title compound, m.p. 221°-222° C.
EXAMPLE 42
N-[N-(Dimethylamino)-N-(N-formylglycyl)]-DL-valyl}-glycine (I; R 1 and R 2 = CH 3 , R 3 = COCH 2 NHCHO, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOH)
A mixture of N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester (6.618 g, 0.020 moles), described in Example 6, and IN NaOH (30 ml) is stirred at room temperature for 90 min. The solution is cooled, rendered acidic with dilute HCl and extracted with chloroform. The extract is washed with brine, dried (MgSO 4 ) and concentrated. The residue is purified by chromatography on silica gel using methanol-chloroform (8:2) as the solvent system. The eluate is concentrated and crystallization of the residue from acetone-isopropyl ether affords the title compound, m.p. 157° - 158° C.
By following the procedure of Examples 41 or 42 other compounds of formula I in which the R 4 or R 6 radical includes an ester may be transformed to their corresponding acids. Examples of such acids prepared in this manner are listed in Table III. In these cases the ester used as starting material is indicated by the example in which it is prepared.
TABLE III__________________________________________________________________________ No. of Example in Which Starting Material isEXAMPLE Prepared Product__________________________________________________________________________43 9 N-cyclohexyl-4-[N-(dimethyl- amino)benzamido]-4-methylglu- taramic acid, m.p. 118 - 119° C44 11 N-[N-(dimethylamino)-N- formyl-DL-valyl]phenylalanine, m.p. 133 - 136° C45 12 N-{1-[N-(dimethylamino)- formamido]cyclohexylcarbonyl}- phenylalanine, m.p. 156 - 157° C46 14 N-[N-(dimethylamino)-N- formyl-DL-valyl]glycine, m.p. 133 - 135° C47 15 N-}1-[N-(dimethylamino)- formamido]cyclohexylcarbonyl}- glycine, m.p. 139 - 142° C__________________________________________________________________________
EXAMPLE 48
N-{[N-(dimethylamino)-N-(N-formylglyclyl)]-DL-valyl}glycinamide (I; R 1 and R 2 = CH 3 , R 3 = COCH 2 NHCHO, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 CONH 2 )
A saturated solution of ammonia in anhydrous methanol (100 ml) is added with cooling to N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester (12.81 g) described in Example 6. The mixture is stirred at room temperature for 4 days. The solvent is removed and the residue subjected to chromatography on silica gel. Elution with chloroform-methanol (98.2) affords the title compound which, after crystallization from acetone, has m.p. 165° - 168° C.
In the same manner but replacing N-{[N-dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester with an equivalent amount of N-[N-(dimethylamino)-N-formyl-DL-valyl]-DL-phenylalanine methyl ester (Example II),
N-{N-[N-(carboxyglycyl)-N-(dimethylamino)-DL-leucyl]-DL-methionine
N-t-butyl ethyl diester (Example 23), or N-[-(p-amino-N-piperidinobenzamido)cyclohexylcarbonyl]glycine ethyl ester Example 48), then N-[N-dimethylamino)-N-formyl-DL-valyl]-DL-phenylalaninamide, m.p. 147°-156° C, N-N-[N-(carboxyglycyl)-N-(dimethylamino)-DL-leucyl]}-DL-methioninamide N-t-butyl ester, separated by chromatography on silica gel into Isomer A, m.p. 84° - 89° C and Isomer B, m.p. 80°- 90° C, and 2-[1-(p-amino-N-piperidinobenzamido)cyclohexanecarboxamido]acetamide, m.p. 198° - 201° C, are obtained, respectively.
EXAMPLE 49
N-{1 -[p-Amino-N-(dimethylamino)benzamido]cyclohexylcarbonyl-DL-phenylalanine methyl ester (1; R 1 and R 2 =CH 3 ; R 3 = p-aminobenzoyl, R 4 and R 5 = (CH 2 ) 5 and R 6 = CH(CH 2 C 6 H 5 )COOCH 3 )
N-{1-[N-(Dimethylamino)-p-nitrobenzamido]cyclohexylcarbonyl-phenylalanine methyl ester (9.5 g), described in Example 13, in 20 ml. of dry methanol is hydrogenated with 5% palladium on charcoal. Thereafter, the catalyst is collected on a filter pad. The filtrate is concentrated and the residue crystallized from acetone-isopropyl ether to give the title compound, m.p. 138°- 139° C.
In the same manner but replacing N-{1-(dimethylamino)-p-nitrobenzamido]cyclohexylcarbonyl}glycine methyl ester (Example 18), or N-{1-[(p-nitro-N-piperidino)benzamido)]cyclohexylcarbonyl }glycine ethyl ester (Example 25), then N-{1-[p-amino-N-(dimethylamino)benzamido]cyclohexylcarbonyl} glycine ethyl ester, m.p. 69° - 71° C, and
N-{1-(p-amino-N-piperidinobenzamido)cyclohexylcarbonyl}glycine ethyl ester, m.p. 92° - 96° C, are obtained, respectively.
EXAMPLE 50
N-[N-(Dimethylamino)-N-(isocyanoacetyl)-DL-valyl]glycine ethyl ester (I; R 1 and R 2 = CH 3 , R 3 = COCH 2 NC, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOC 2 H 5 )
A solution of N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester (4.0 g), described in Example 6, in dry methylene chloride (12 ml) is placed in a 3-neck flask fitted with mechanical stirrer, reflux condenser and drying tube (KOH). Redistilled triethylamine is then added (5.08 ml) followed by dropwise addition of a solution of phosgene in benzene (12 ml. of a 12.5% solution). The mixture is stirred an additional 30 min. at room temperature, the precipitate is then filtered off, the filtrate concentrated under reduced pressure to dryness (at temperature < 40° ). The residue is diluted with anhydrous benzene (40 ml) and filtered once more. The filtrate is evaporated to dryness and the residue purified by column chromatography using silica gel. Elution with benzene-ethyl acetate (1:l) provides the isonitrile as a yellow solid. To remove the color the material is dissolved in benzene and the solution is filtered through a short column of alumina (Activity II. The fractions containing the isonitrile are pooled and the solvent removed at low temperature (<40° ) under reduced pressure the residue if triturated with anhydrous diethylether to give the title compound, m.p. 119-120.5° C.
By following the procedure of Example 50 but replacing N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ether ester with an appropriately substituted compound of formula I in which R 3 represents COCH 2 NHCHO, prepared by the procedure of Example 6 or 7, then the corresponding compounds of formula I in which R 3 is COCH 2 NC are obtained. For example, N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-leucyl}-DL-methionine ethyl ester gives N-[N-(diethylamino)-4-(isocyanoacetyl)-DL-leucyl]-DL-methionine ethyl ester.
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α-Hydrazinocarboxamide and α-(α'-acylhydrazino)-carboxamide derivatives of formula I ##STR1## in which R 1 and R 2 each are lower alkyl or R 1 and R 2 together with the nitrogen atom to which they are joined form a piperidino or morpholino radical; R 3 is hydrogen, lower alkanoyl, benzoyl, p-nitrobenzoyl, p-aminobenzoyl, p-chlorobenzoyl, isocyanoacetyl, or protected amino acyl radicals, for example, N-formylglycyl or ##STR2## (N-carbobenzoxyglycylglycyl); R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is hydrogen or phenyl and R 8 is hydrogen or lower alkyl; R 5 is hydrogen or lower alkyl; or R 4 and R 5 together with the carbon atom to which they are joined form a cyclohexylidene radical; and R 6 is a cyclohexyl or CHR 9 COY wherein R 9 is hydrogen or benzyl and Y is hydroxyl, lower alkoxy or amine, with the provisos that when Y is hydroxyl then R 8 is hydrogen, that when Y is lower alkoxy than R 8 is lower alkyl and that when Y is amino R 4 is lower alkyl, are disclosed herein along with the related α-hydrazino-carboxamide and α-(α'-acylhydrazino)carboxamide compounds of formula III ##STR3## in which R 1 , R 2 , R 3 , R 5 and R 7 are as defind above and Y is lower alkoxy. These compounds possess antibacterial activity. Methods for their preparation and use are disclosed also.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is the U.S. national stage application of International Patent Application No. PCT/EP2008/065980, filed Nov. 21, 2008, which claims the benefit of U.S. Provisional Patent Application No. 61/004,480, filed Nov. 28, 2007, the disclosures of which are hereby incorporated by reference in their entirety, including all figures, tables and amino acid or nucleic acid sequences.
The Sequence Listing for this application is labeled “Seq-List.txt” which was created on Mar. 25, 2010 and is 29 KB. The entire contents of the sequence listing is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a new splice variant of BANK1, the use of SNPs associate with BANK1 for diagnostics and the use of antagonists to modulate BANK1 and/or the BANK1 pathway.
BACKGROUND OF THE INVENTION
Genetic techniques allow the identification of single nucleotide polymorphisms (SNPs) in individuals. SNPs are changes in a gene in one single nucleotide. Identification of SNPs can be correlated with a biological pathway having implications for a particular disease. The polymorphisms may be correlated also with a predisposition or risk for a disease by application of statistical analyses. Accordingly, targeting a particular biological pathway related to a disease is a means to treat such disease.
B-cell scaffold protein with ankyrin repeats (BANK1) is expressed in B cells and is tyrosine phosphorylated upon B-cell antigen receptor (BCR) stimulation. The BANK1 gene has 284 kb. BANK1 is an adaptor protein (6, 7) expressed mainly in B cells. The two full length isoforms of 785 and 755 amino acids, differ by 30 amino acids in the N-terminal region coded by the alternative exon 1A ( FIG. 1 e ) and contain ankyrin repeat motifs and coiled-coil regions—structures highly similar between BANK1, BCAP and D of adaptor proteins (8). B cell activation through BCR engagement leads to tyrosine phosphorylation of BANK1, which in turn promotes its association with the protein tyrosine kinase Lyn and the calcium channel IP3R (3). BANK1 serves as a docking station bridging together and facilitating phosphorylation and activation of IP3R by Lyn and the consequent release of Ca 2+ from endoplasmic reticulum stores (3, 9). It was previously found that IP3R associates with the SNP rs10516487 lying within a region essential for binding of IP3R.
The BANK1 SNPs rs17266594 and rs3733197 have also been described in the literature.
None of the above SNPs have been described in the literature to be useful for the prediction of an inflammatory, auto-immune or neurological disease.
BANK1 and the pathway it is involved in, is considered to have implications for inflammatory and auto-immune disorders. In particularly, BANK1 is expressed in B-cells and therefore the pathway wherein BANK1 is involved has an implication for diseases associated with B-cells, e.g. Systemic Lupus Erythematosus (SLE). Multiple Sclerosis (MS) is related to T-cells, however, also the role of B-cells has been discussed in this disease. Accordingly, polymorphisms in the BANK1 gene may be used to diagnose a predisposition or risk for MS. Moreover, the BANK1 pathway may have implications for MS. In consequence, targeting this pathway and its modulation may represent a means to prevent or treat MS.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a novel splice variant of BANK1 is provided.
According to another aspect of the invention, a method is provided for diagnosing an individual for the predisposition of, the risk of developing or suffering from an auto-immune or inflammatory disease wherein the pathway of BANK1 is involved.
According to another aspect of the invention, a method for the treatment and/or prevention of an auto-immune or inflammatory disease is provided using an antagonist targeting BANK1, the biological pathway of BANK1 and/or factors connected to the BANK1 pathway.
According to another aspect of the invention, a method of treating diseases is provided wherein the pathway of BANK1 is involved using an antagonist targeting BANK1, the biological pathway of BANK1 and/or factors connected to the BANK1 pathway.
BRIEF DESCRIPTION OF THE SEQUENCES AND DRAWINGS
SEQ ID NO: 1, 3, 5 are the nucleic acid sequences of the BANK1 delta 2 splice variant of human, chimpanzee and mouse, respectively.
SEQ ID NO: 2, 4, 6 are the amino acid sequences of the BANK1 delta 2 splice variant of human, chimpanzee and mouse, respectively.
FIG. 1 a - 1 e . Association of rs17266594 with increased levels of the full-length isoform of BANK1. (a) Total expression of BANK1 gene in separated mononuclear cell subpopulations. (b) RT-PCR of the coding part of BANK1 amplified from total human spleen cDNA reveals two bands on a gel. 1 kb ladder (New England Biolabs) is shown on the left. The identity of both bands, 2.3 kb upper band and 1.9 kb smaller band, was confirmed by sequencing analysis. (c) Relative mRNA expression levels of the full-length and delta 2 isoforms of BANK1, as determined by quantitative real-time RT-PCR on total RNA purified from human PBMCs. Data represent mean±S.D. 39 individuals with TT for the branch point site SNP, 34 with TC and 10 with CC genotype were analysed. Full-length transcript: TT versus CC, P=0.0004 (Student's t-test); delta 2 transcript: TT versus CC, P=0.0088. (d) Total BANK1 expression was not significantly affected by SNP rs17266594. (e) Schematic structure of the 5′-end of the gene. SNP rs17266594 located in the branch point site of intron 1 alters splicing efficiency of the full-length and delta 2 transcripts. SNP rs10516487 results in non-synonymous substitution of Arg 61 to His. Alternative splicing gives rise to two isoforms, full-length and delta 2 with in-frame deletion of entire exon 2 of BANK1. Thus, the short protein isoform lacks the putative domain for IP3R binding and could function as a dominant negative isoform attenuating signaling from the full-length protein.
IP3R BD—inositol 1,4,5-triphosphate receptor binding domain, Lyn BD—tyrosine kinase Lyn binding domain.
FIG. 2 a Linkage disequilibrium and haplotype block structure across BANK1, Data calculated with Haploview analysis of our data using the Swedish cases and controls run for 30 SNPs across the gene.
FIG. 2 b R2 for all SNPs across BANK1.
FIG. 2 c FIGS. 2 a and 2 b (combined)
FIG. 3 Frequencies of the haplotypes constructed with rs17266594 and rs10516487 (74.1% TG, 24.2% CA), and allele frequencies for rs3733197 (68.0% G, 32.0% A). The figure also shows the frequencies of the haplotypes when including all three SNPs (64.1% TGG, 10.1% TGA, 20.3% CAA, 3.8% CAG). Data is calculated using all populations, combined.
DETAILED DESCRIPTION OF THE INVENTION
The following paragraphs contain definitions used according to the invention and are intended to apply uniformly throughout the specification and claims unless otherwise expressly set out definition provides a broader definition.
The present invention is directed to an isolated nucleic acid sequence comprising the sequence of BANK1 lacking exon 2. In a preferred embodiment the nucleic acid is of human, chimpanzee, or mouse origin. As a reference for the BANK1 sequence one may refer to Nature 431 (7011), 931-945 (2004).
In the human BANK1 sequence as described in NCBI's human genome assembly build 36, chromosome 4 the exons/introns are as follows:
Exon1: 102930919-102931130
Intron1: 102931131-102969987
Exon2: 102969988-102970386
Intron2: 102970387-102995214
Exon3: 102995215-102995369
Intron3: 102995370-103002705
Exon4: 103002706-103002844
Intron4: 103002845-103010684
Exon5: 103010685-103010824
Intron5: 103010825-103035484
Exon6: 103035485-103035590
Intron6: 103035591-103058172
Exon7: 103058173-103058369
Intron7: 103058370-103161693
Exon8: 103161694-103161772
Intron8: 103161773-103165380
Exon9: 103165381-103165689
Intron9: 103165690-103170139
Exon10: 103170140-103170445
Intron10: 103170446-103184018
Exon11: 103184019-103184087
Intron 11: 103184088-103200390
Exon12: 103200391-103200569
Intron12: 103200570-103203254
Exon13: 103203255-103203318
Intron13: 103203319-103211454
Exon14: 103211455-103211484
Intron14: 103211485-103212524
Exon15: 103212525-103212580
Intron15: 103212581-103213863
Exon16: 103213864-103213928
Intron16: 103213929-103214184
Exon17: 103214185-103214918
It is preferably possible that only part of the BANK1 exon 2 is deleted. Such a molecule is equally useful according to the invention.
In one embodiment the isolated nucleic acid comprises SEQ ID NO: 1, 3, or 5, or the complement of said nucleic acid sequence.
In one embodiment the invention relates to an isolated nucleic acid which:
a) hybridizes under high stringency conditions; or b) exhibits at least about 85%, preferably at least about 90% and more preferably at least 95% identity over a stretch of at least about 30 nucleotides
with a nucleic acid selected from the group consisting of SEQ ID NO: 1, 3, or 5, or a complement of said nucleic acid sequence.
Another embodiment of the invention is a polypeptide encoded by any of the nucleic acid sequences as mentioned above.
Another embodiment is a vector comprising a nucleic acid as described above, preferably a nucleic acid selected from the group consisting of SEQ ID NO: 1, 3, or 5, or a complement of said nucleic acid sequence.
Preferably the vector containing said nucleic acid molecule is operatively linked to at least one expression control sequence allowing expression in prokaryotic or eukaryotic host cells of the encoded polypeptide.
Another embodiment is a host cell transformed with a vector or a nucleic acid as described above.
Yet another embodiment of the invention is a method for making a polypeptide as described above comprising culturing a host cell as defined above under conditions in which the nucleic acid is expressed, and recovering the polypeptide encoded by said nucleic acid from the culture.
Another embodiment is a method for genotyping comprising the steps of:
a. Isolating a nucleic acid from a sample of an individual; and b. Determining whether in rs10516487 a guanine or an adenine is present, in rs17266594 a tyrosin or a cytosine is present, in rs3733197 an adenine or a guanine is present in the biallelic marker.
In a preferred method the identity of the nucleotides at said biallelic markers is determined for both copies of said biallelic markers present in said individual's genome.
The method for genotyping according to the invention is preferably performed by a microsequencing assay. The method preferably further comprises amplifying a portion of a sequence comprising the biallelic marker prior to said determining step. Preferably said amplifying is performed by PCR. The method according to the invention further comprises the step of correlating the result of the genotyping steps with a risk of suffering or a predisposition for an auto-immune disease or inflammatory disease.
In a preferred embodiment the method is performed, wherein the presence of a guanine in rs10516487, a tyrosine in rs17266594 and an adenine in rs3733197 in said individual indicates that said individual suffers from, has a predisposition for or is at risk of suffering from said auto-immune disease or inflammatory disease.
The method of the invention preferably is applied wherein the disease is Systemic Lupus Erythrematosus or Multiple Sclerosis.
Now that the inventors have established the association between BANK1 and SLE and MS or related diseases, it should be understood that additional susceptibility alterations can be identified within said gene or polypeptide, e.g., following the methodology disclosed in the examples.
The presence of an alteration in the BANK1 gene may be detected by any technique known per se to the skilled artisan, including sequencing, pyrosequencing, selective hybridisation, selective amplification and/or mass spectrometry including matrix-assisted laser desorption/ionization time-of-flight mass spectrometry (MALDI-TOF MS) (Gut et al., 2004). In a particular embodiment, the alteration is detected by selective nucleic acid amplification using one or several specific primers. The alteration is detected by selective hybridization using one or several specific probes.
Further techniques include gel electrophoresis-based genotyping methods such as PCR coupled with restriction fragment length polymorphism analysis, multiplex PCR, oligonucleotide ligation assay, and minisequencing; fluorescent dye-based genotyping technologies such as oligonucleotide ligation assay, pyrosequencing, single-base extension with fluorescence detection, homogeneous solution hybridization such as TaqMan, and molecular beacon genotyping; rolling circle amplification and Invader assays as well as DNA chip-based microarray and mass spectrometry genotyping technologies (Shi et al., 2001).
Furthermore, RNA expression of altered genes can be quantified by methods known in the art such as subtractive hybridisation, quantitative PCR, TaqMan, differential display reverse transcription PCR, serial, partial sequencing of cDNAs (sequencing of expressed sequenced tags (ESTs) and serial analysis of gene expression (SAGE)), or parallel hybridization of labeled cDNAs to specific probes immobilized on a grid (macro- and microarrays and DNA chips. Particular methods include allele-specific oligonucleotide (ASO), allele-specific amplification, fluorescent in situ hybridization (FISH) Southern and Northern blot, and clamped denaturing gel electrophoresis.
Protein expression analysis methods are known in the art and include 2-dimensional gel-electrophoresis, mass spectrometry and antibody microarrays (Freeman et al., 2004 and Zhu et al., 2003).
Sequencing can be carried out using techniques well known in the art, using automatic sequencers. The sequencing may be performed on the complete gene or, more preferably, on specific domains thereof, typically those known or suspected to carry deleterious mutations or other alterations.
Amplification may be performed according to various techniques known in the art, such as by polymerase chain reaction (PCR), ligase chain reaction (LCR) and strand displacement amplification (SDA). These techniques can be performed using commercially available reagents and protocols. A preferred technique is allele-specific PCR.
Nucleic acid primers useful for amplifying sequences from the BANK1 gene are able to specifically hybridize with a portion of the BANK1 gene that either flanks or overlaps with a susceptibility alteration. The primer sequence overlaps with the alteration when said alteration is contained within the sequence of the BANK1 gene to which the primer hybridizes. The primer sequence flanks the alteration when the primer hybridizes with a portion of the BANK1 gene that is preferably located at a distance below 300 bp of said alteration, even more preferably below 250, 200, 150, 100, 50, 40, 30 or 20 bp from said alteration. Preferably, the primer hybridizes with a portion of the BANK1 gene that is at 5, 4, 3, 2, 1 bp distance or immediately adjacent to said alteration.
In another embodiment the method for detecting whether an individual has a predisposition for or is at risk of an auto-immune disease or inflammatory disease according to the invention comprises the steps:
a. Isolating the nucleic acid of an individual; b. Detecting and quantifying the BANK1 full length nucleic acid; c. Detecting and quantifying the BANK1 delta 2 nucleic acid; d. Determining the ratio b./c. and/or c./b. of the results of step b. and c.
In this method the nucleic acid is preferably a mRNA, cRNA or cDNA.
In step d. of the above method the determined ratio is an indication of the disease or its increased susceptibility. The more full length mRNA and the less delta 2 splice variant the more risk of disease an individual has. In particular, the higher this ratio is in the b./c correlation and the lower this ratio is in the c./b. correlation the higher is the risk to develop an auto-immune or inflammatory diseases, in particular SLE or MS.
The inventors have found that the total BANK1 mRNA is not influenced by the presence of particular SNPs. IN particular SNPs rs10516487, rs17266594 and rs3733197 do not change the total amount of BANK1 mRNA content. Accordingly the ratio of full length to delta 2 splice variant of BANK1 mRNA or cDNA is not influenced by the presence of the SNPs of the invention. Preferably the ratio b./c. or c./b is about 1. The ratios useful in the invention are as described above either b./c. or c./b.
A change in rs17266594 from TT to TC to CC has an influence in the amount of delta 2 BANK1 splice variant mRNA detectable. A ration of b./c. greater than 1, preferably significantly greater than 1 is indicative of a suffering from, or a predisposition for auto-immune or inflammatory diseases, preferably Systemic Lupus Erythrematosus or Multiple Sclerosis. A ration of c./b. less than 1, preferably significantly less than 1 is indicative of a suffering from, or a predisposition for auto-immune or inflammatory diseases, preferably Systemic Lupus Erythrematosus or Multiple Sclerosis. A change in this SNP from TT to CC may be most reliably be used to make this prediction. The suffering or predisposition may be expressed by calculation of the odd ration (OD). It will be appreciated by the skilled person that any method detecting and/or calculating a change in the SNP rs17266594 and/or mRNA or cDNA of BANK1 full length and/or delta 2 splice variant may be used to detect a predisposition for auto-immune or inflammatory diseases. In one embodiment the invention may be applied by comparing the mRNA of the BANK1 delta 2 splice variant of a sample with a control. The control may be chosen from one sample or a number of pooled samples.
The SNPs rs10516487 and rs3733197 can also be used to predict a suffering or predisposition and may serve as indirect markers. According to the invention also other SNPs may be used as predictive markers if a linkage with the above markers can be detected. Such a linkage, preferably strong linkage, is expressed by the LD and is preferably D′ 0.7, preferably D′ 0.8, more preferably D′ 0.9. Such markers can be identified by standard techniques known in the art.
In another embodiment the invention relates to a method for the treatment and/or prevention of diseases selected from auto-immune or inflammatory diseases using an antagonist targeting BANK1, the biological pathway of BANK1 and/or factors connected to the BANK1 pathway. Preferably disease is Systemic Lupus Erythrematosus or Multiple Sclerosis.
The antagonist may be any molecule that antagonizes partly or essentially completely the targets of interest. Preferably the antagonist targets BANK1, LYN and/or IP3R or their interaction. Preferably the antagonist targets the nucleic acid of BANK1. In one embodiment the antagonist is an anti-sense RNA, siRNA, an Aptamer, a peptide or a small molecule. In another embodiment the antagonist is an antibody or antibody fragment specifically binding to the targets BANK1, LYN and/or IP3R. Particularly preferred is an antagonist that binds specifically to IP3R or interferes with the function of IP3R. In this manner it can be preferably achieved that the impact of B-cells involved in the disease development or manifestation of the disease is positively modulated, preferably inhibited.
The preferred SNPs as used in the invention are as follows:
Biallelic marker
Alternative nucleotides
rs10516487
G/A
rs17266594
T/C
rs3733197
A/G
The risk allel of rs10516487 is G. The risk allel of rs17266594 is the T and of rs3733197 is A. It will be understood that also other SNPs in Linkeage Disequilibrium (LD) may be used in the sense of the invention as described herein.
All references cited in this application are herewith incorporated by reference. In the following the present invention shall be illustrated by means of the following examples, which are not construed to be viewed as limiting the scope of the invention.
EXAMPLES
A set of 279 Swedish cases with SLE and 515 Swedish controls were genotyped for the 100 k Affymetrix SNPs array. After filtering, data from 85042 SNPs was used. As our purpose was to identify non-MHC genes and important functional polymorphisms, we proceeded to perform an analysis of the genomic location of the associated SNPs within known genes, discarding genomic deserts. Analysis of the data showed that among all the non-MHC-associated SNPs, one (rs10516487) was a non-synonymous substitution of arginine to histidine (triplet cGc→cAc, Arg→His) at amino-acid position 61 (from exon1A) of the BANK1 translated protein (allelic association, P=6.4×10 −3 ; genotypic association, P=2.01×10 −2 ). This SNP was ranked as #679 across the whole genome scan in the allelic association analysis and as #2148 in the genotypic test. The estimated FDR (False Discovery Rate) was 71.1% and 77.5% for these selections, respectively (2). Four more SNPs within BANK1 showed also association with SLE in the Affymetrix scan (Supplementary Table 1). The described B cell-specific expression of BANK1 and its potential role in B cell receptor-mediated activation led us to pursue this gene (3, 4).
We genotyped 30 SNPs in Swedish cases and 352 controls including the Affymetrix SNPs covering the complete 284 kb of the BANK1 gene. Two SNPs were not polymorphic in our population. Individual SNP analysis showed that 9 SNPs including rs10516487 were associated (Table 1). Using the solid-spine LD (Linkage Disequilibrium) haplotype block definition available from Haploview, 5 LD blocks could be recognized. All of the SNPs showing genetic association were lying on block 2, 3 and 4. No genetic association was detected for SNPs located in block 5 (Table 1, Supplementary Table 2 and FIG. 2 a ). To confirm the genetic association, we genotyped four more sets of cases and controls from Germany, Spain, Italy and Argentina for rs10516487. We could corroborate the genetic association with all the European sets, although the Argentine set showed a clear tendency without reaching significance (Table 2). We performed homogeneity and combinability analysis of the sets using the Breslow-Day method. As the data could be combined, a meta-analysis was performed on all the sets comprising 3971 individuals. The Mantel-Haenzel (MH) test revealed a P value reaching genome-wide significance and a pooled odds ratio of 1.38 (X 2 =39.243, P=3.74×10 −10 , 95% CI 1.25-1.53) for the allelic association. A significant genotypic association was also observed (Table 2).
We initiated a detailed analysis of BANK1 expression and structure. We observed that indeed and as described, BANK1 is primarily expressed in CD19+ B cells at high levels, while very low expression could be detected in CD4+, CD8+ and CD14+ cells ( FIG. 1 a ). We then sequenced the proximal promoter region, exon1A, exon1B, and exon2 (where haploblock 2 is located) and 500 bp up and downstream of these exons in 24 SLE patients and 8 controls. No novel SNPs were found for these regions. In order to clone BANK1 cDNA in an expression vector for functional analysis, we amplified full-length cDNA with distal primers. Surprisingly, two bands were detected on a gel after PCR ( FIG. 1 b ). Subsequent cloning and sequencing revealed a new isoform with an in-frame deletion of the entire exon 2 (delta 2 isoform of BANK1). We analyzed cDNA from 83 healthy individuals and 30 SLE patients and found that this isoform was present in each sample, indicating that it is constitutively spliced. Moreover, this isoform was detected by PCR amplification of cDNA from chimp and mouse spleen as well, suggesting its conserved expression across species. Thus, we detected transcripts for three BANK1 isoforms, two full-length using exon1A or exon1B and a delta 2 isoform.
We next performed quantitative analysis of isoform expression in peripheral blood mononuclear cells. First, the relative levels of the two full-length isoforms, beginning with exon 1A and exon 1B, were determined. Since the latter transcript was present at very low levels, we continued the analysis measuring common full-length isoform levels. We noticed that the ratio of the full-length (FL) isoform to delta2 was not constant, which would be expected if delta 2 were equally expressed regardless of the genotypes of the analyzed samples. On the contrary, samples could be divided into groups according to the FL/delta 2 isoform ratio. After close examination of the genomic sequences surrounding exon 2 where putative signals affecting splicing could be located, one SNP, rs17266594, was found to lie in the putative branch point site and could potentially affect splicing. When expression data was re-grouped according to this SNP, a clear difference between the genotypes could be observed ( FIG. 1 c ). Individuals homozygous for the T allele and thus having the classical structure of the branch point site (5) (YNYTG A YYN), showed equal expression of both isoforms, while expression of the full-length transcript was significantly suppressed (up to 40%) with concomitant upregulation of delta 2 isoform expression in individuals homozygous for the minor allele C. Total BANK1 transcription level was not significantly affected by the SNP ( FIG. 1 d ). Genotyping of all of our sets of cases and controls for rs17266594 showed that the T allele was associated with SLE (Table 2; P=4.74×10 −11 , OR=1.42; 95% Cl 1.28-1.58).
Both SNPs, rs17266594 and rs10516487, are separated by 153 nucleotides (nt) and are in strong LD (D′=0.95; R2=0.90; FIG. 2 b ). The T allele of the first SNP and the G allele of second one were found in the same risk haplotype associated with SLE (Table 2, bottom; P=4.75×10 −6 ; OR=1.30, 95% Cl 1.16-1.45) and FIG. 3 .
We identified five non-synonymous substitutions in the databases. While most SNPs were non-polymorphic, one, rs3733197, an alanine to threonine substitution in amino acid position 383 (triplet Gca→Aca) in exon 7 coding for the ankyrin repeat-like motif, showed association in the combined sample (X 2 =16.576; P=4.67×10 −5 (OR=1.23, 95% Cl 1.11-1.36;) although it had not shown association in our first analysis on Swedish individuals nor in the whole Scandinavian set (Table 1 and Supplementary Table 3). This SNP is in haploblock 4 ( FIG. 2 a ) 88211bp apart from rs10516487 (D′=0.72; R2=0.39) and rs17266594 (R2=0.27), could segregate with the risk haplotype composed of the other two SNPs in some cases ( FIG. 3 ) and could be a minor functional polymorphism.
Thus, herein we identify three functional polymorphisms in BANK1 associated with SLE. The associated T allele of rs17266594 correlates with increased levels of the full-length isoform of BANK1. Thus, both polymorphisms in combination would lead to the achievement of one effect—high expression of a “more active” protein—through more efficient splicing of the full-length transcript that encodes a protein with an arginine residue in the IP3R binding domain. Since the delta 2 isoform lacks the entire exon 2 coding for IP3R binding and PH domains, it possibly functions as a dominant negative isoform thereby attenuating BANK1-mediated signaling ( FIG. 1 e ).
Importance of mutations in ankyrin motifs for interaction with IP3R was recently highlighted by the discovery linking single amino acid substitutions in the adaptor protein ankyrin-B with cardiac arrhythmia and sudden cardiac death (10). While the alanine is associated with SLE, the rare allele A of rs3733197 might create a potential site for threonine kinases (11).
B cells are the major cell type affected in SLE. Novel therapies are aimed at depleting hyperactivated B cells that may function not solely as autoantibody producing cells, but also as important regulators of the innate and adaptive immune responses through antigen presentation and cytokine-mediated signaling (12). Functional and expression abnormalities of signaling molecules in B cells have been described in lupus. Of particular interest is the fact that Lyn, a binding partner of BANK1 is of key importance in human and mouse lupus autoimmune disease (13-18)
B cell hyperresponsiveness or a lack of control of B cell activation during immune responses. The precise role of BANK1 in BCR-mediated signaling remains unclear since two reports published so far contain conflicting data regarding the stimulatory or inhibitory role of BANK1 on B cell activation. Given the previously unreported existence of the alternative splicing of exon 2 we can speculate that the negative role for BANK1 assigned for the KO model was in part because of the remaining expression of the delta 2 isoform, as this exon was targeted by the KO-construct (4).
DNA Samples
279 cases and 515 controls were genotyped for the 100 k array. Of these individuals 279 cases and 352 controls were typed for the BANK1 coverage shown in Table 1.
For the functional polymorphisms an additional 185 Swedish patients were genotyped and 465 of the controls were available for genotyping of rs17266594 and rs3733197. We also added for the final MH (Mantel Haentsel) analysis and OR (Odds Ratio) estimation 84 Danish cases with the Swedish cases comprising the Scandinavian set shown in Table 2. The replication sets included 384 North German patients and 374 controls, 288 Argentine patients and 372 controls, 286 Italian patients and 252 controls. The Spanish cohort included 799 patients and 542 controls from several regions in Spain. 707 of the patients and 469 of the controls were genotyped for rs10516487 and rs3733197, and 678 of the patients and 457 of the controls for rs17266594. The reason for this is that DNA from a number of controls was not available. The German, Spanish and Argentine patients have all been previously described (19). The Italian cases are a multicenter collection of patients and their matched controls from Rome, Siena, Milan and Naples, that is North and Mid-Italy. All patients fulfil the 1982 ACR (American College of Rheumatology) criteria for the classification of SLE (20).
Genotyping
Genotyping of the 100 k Affymetrix array was performed according to the manufacturers instructions. Fine mapping and replication for SNPs rs10516487, rs17266594 and rs3733197 were done using TaqMan SNP genotyping assays (Applied Biosystems, Foster City, Calif.). The Affymetrix genotyping and fine mapping were performed at Serono Genetics Institute in Evry, France (now MerckSerono SA). The functional polymorphism replications were done. One hundred and six of samples were genotyped twice for verification showing 100% concordance. Genotyping success rate for all the samples was over 92%.
Statistical Analysis
For the 100K Affymetrix whole-genome scan analysis, pre-processing filters have been applied: SNPs have been discarded if (i) the proportion of missing genotypes is higher than 5%, (ii) the relative minor allele frequency is lower than 1% or (iii) the probability that the observed genotype distribution results from sampling a SNP which follows the Hardy-Weinberg equilibrium is lower than 0.02. Only SNPs from autosomal chromosomes have been kept for the sake of homogeneity between male and female individuals. SNP sequences have been mapped onto NCBI 36 human genome assembly and SNPs with multiple localizations have been discarded. For each remaining SNP, genotypic and allelic frequencies in cases and controls are calculated and the corresponding probability values are computed using exact (non-asymptotic) and unbiased algorithms (21). The False-Discovery Rate (FDR) is then estimated using the method described by Former, et al. (2).
For fine mapping analyses, genetic association, haplotype estimation, LD and R2 were all estimated using Haploview (v4.0RC2). The Breslow-Day test of combinability and the Mantel-Haenzel test were performed using the StatsDirect software (v2.4.6). As the Breslow-Day test showed combinability of the strata, the MH test for fixed effects was used in the analysis. Haplotypes were estimated using the PHASE software (v2.1) (22, 23). Genotypic odds ratios were calculated using the Unphased software (v3.0.9) (24).
Sequencing
DNA fragments for sequencing were amplified with the corresponding primers (see Supplementary Table 4), purified from agarose gel with QIAquick gel extraction kit (Qiagen) and sequenced using BigDye Terminator 3.1 (Applied Biosystems) at the Uppsala Genome Center.
RNA Purification and BANK1 Expression Analysis
Total RNA was purified with TRIZOL Reagent (Invitrogen) from peripheral blood mononuclear cells (PBMCs) obtained with agreed consent from healthy donors and lupus patients. 2 μg of RNA were reverse-transcribed with 2 U of MultiScribe transcriptase in PCR buffer II containing 5 mM MgCl 2 , 1 mM dNTPs, 0.4 U of RNase inhibitor and 5 μM oligo-dT. All reagents were purchased from Applied Biosystems. cDNA synthesis was performed at 42° C. for 80 min, and then the reaction was terminated at 95° C. for 5 min. All cDNA samples were diluted to 15 ng/μl.
BANK1 expression was determined by real-time PCR on an ABI PRISM 7700 Sequence Detector (Applied Biosystems) with SDS 1.9.1 software. Total Bank1, both alternative full-length isoforms and delta2 isoform were quantified with SYBR Green and relevant primers (see Supplementary Table 4). We performed initial denaturation at 95° C. for 5 min followed by 45 cycles of PCR (95° C. for 15 s, 62° C. for 15 s and 72° C. for 30 s). PCR buffer provided with enzyme was supplemented with 3 mM MgCl 2 , 200 μM of each of dNTPs, primers, SYBR Green (Molecular Probes), 15 ng of cDNA and 0.5 U of Platinum Taq polymerase (Invitrogen). Expression levels were normalized to the levels of TBP in the same samples amplified with commercial reagents (Applied Biosystems). All experiments were run in triplicate. Independent cDNA synthesis was carried out twice.
Cloning of Human, Mouse and Chimpanzee BANK1 delta 2 Isoform
Purification of total RNA from mouse spleen and cDNA synthesis were conducted as described above for the human PBMCs. Total RNA from chimpanzee ( Pan troglodytes ) spleen was kindly provided by Drs. Tomas Bergström and Lucia Cavelier, Uppsala University. Human gene was amplified from Human Spleen BD Marathon-Ready cDNA (Clontech). After initial denaturation at 95° C. for 5 min, 35 cycles (95° C. for 20 s, 60° C. for 15 s and 72° C. for 2 min 30 s) were performed in PCR buffer containing 2 mM MgSO 4 , 200 μM of each of dNTPs, 0.4 μM of each of the corresponding primers (see Supplementary Table 4), and 0.5 U of Platinum Taq-High Fidelity enzyme (Invitrogen). Chimp cDNA was amplified with human-specific primers. PCR products were purified from agarose gel and cloned in pCR 4-TOPO vector (Invitrogen) according to the manufacturer's instructions. Plasmid DNA from positive clones was purified with QIAprep Spin Miniprep kit (Qiagen) and verified by sequencing.
Accession Codes
BANK1 delta 2 transcripts were deposited in Genbank under the following accession numbers EU051376 for human, EU051377 for chimpanzee and EU051378 for mouse.
URLs. Haploview: www.broad.mit.edu/mpg/haploview/; GraphPad Software: http://www.graphpad.com; Protein analysis: http://www.ebi.ac.uk/saps/; http://smart.embl-heidelberg.de/, http://ca.expasy.org/prosite/, http://www.cbs.dtu.dk/services/NetPhos/.
TABLE 1
Association of SNPs in BANK1 in Swedish SLE
Associated
SNP rs name
allele
Chi Sq
P Value
rs7675129
T
0.147
0.701
rs11726012
G
0.495
0.4963
rs11097755
C
0.406
0.524
rs4522865
A
4.758
0.0292
rs4496585
A
1.933
0.1644
rs4572885
T
4.442
0.0355
rs10516487
G
7.185
0.0074
rs10516486
C
10.041
0.0015
rs17200824
A
2.780
0.0955
rs6849308
C
7.347
0.0067
rs10516482
C
8.709
0.0032
rs10516483
C
9.121
0.0025
rs10516484
A
0.577
0.4476
rs4493533
C
0.833
0.3614
rs3733197
A
0.006
0.9402
rs2631271
G
6.793
0.0092
rs2850390
C
1.032
0.3096
rs2631265
T
0.001
0.9815
rs2631267
G
0.048
0.827
rs2631268
T
1.375
0.2409
rs10516491
C
2.388
0.1223
rs1872701
G
1.454
0.2278
rs2850393
T
0.313
0.5759
rs2850396
C
0.344
0.5575
rs10516490
G
0.311
0.5769
rs10516489
T
0.312
0.5712
rs10516488
G
0.537
0.4635
rs1395306
T
1.739
0.1872
SUPPLEMENTARY TABLE 1
BANK1 SNPs in the 100k Array
SNP
rs number
Position
(-log) P value
SNP_A-1701374
rs10516487
103108254
2.27
SNP_A-1701494
rs10516486
103108454
2.79
SNP_A-1664926
rs6849308
103133261
2.22
SNP_A-1706628
rs10516482
103137348
2.52
SNP_A-1744756
rs10516483
103149083
3.25
SNP_A-1683131
rs2631271
103271574
n.s.
SNP_A-1697391
rs10516489
103331537
n.s.
TABLE 2
Genotypic, Allelic and Haplotypic Association of rs10516487 (R61H) and rs17266594 in five sets of SLE cases and controls and joint analysis with Mantel-Haenz
Population
GG
GA
AA
Chi square
P-Value
Odds ratio (CI) a
Allele G
Allele A
P-Value
Odds ratio (CI)
rs10516487
Scandinavian SLE
Cases (536)
309 (57.6%)
200 (37.3%)
27 (5.0%)
11.7874
0.0028
GG: 2.12 (1.29-3.47)
818 (76.3%)
254 (23.7%)
7.27E−04
1.39 (1.14-1.68)
Controls (565)
276 (48.8%)
238 (42.1%)
51 (9.0%)
GA: 1.59 (0.96-2.63)
790 (69.9%)
340 (30.1%)
Argentina SLE
Cases (255)
164 (64.3%)
75 (29.4%)
16 (6.3%)
3.8013
0.1495
GG: 1.41 (0.73-2.72)
403 (79%)
107 (21%)
0.0564
1.31 (0.98-1.74)
Controls (337)
190 (56.4%)
121 (35.9%)
26 (7.7%)
GA: 1.01 (0.51-2.00)
499 (74.3%)
173 (25.7%)
Germany SLE
Cases (312)
181 (58.0%)
118 (37.8%)
13 (4.2%)
11.8503
0.0027
GG: 2.60 (1.32-5.14)
480 (76.9%)
144 (23.1%)
8.13E−04
1.52 (1.18-1.95)
Controls (368)
166 (46.1%)
163 (45.3%)
31 (8.6%)
GA: 1.73 (0.87-3.44)
495 (68.8%)
225 (31.2%)
Italy SLE
Cases (279)
166 (59.5%)
100 (35.8%)
13 (4.7%)
7.5139
0.0234
GG: 2.49 (1.22-5.09)
432 (77.4%)
126 (22.6%)
0.0078
1.46 (1.09-1.94)
Controls (245)
123 (50.2%)
98 (40.0%)
24 (9.8)
GA: 1.88 (0.91-3.91)
344 (70.2%)
146 (29.8%)
Spain SLE
Cases (702)
414 (59.0%)
243 (34.6%)
45 (6.4%)
11.3579
0.0034
GG: 1.26 (0.77-2.06)
1071 (76.3%)
333 (23.7%)
0.0065
1.30 (1.07-1.58)
Controls (446)
219 (49.1%)
197 (44.2%)
30 (6.7%)
GA: 0.82 (0.50-1.35)
635 (71.2%)
257 (28.8%)
Pooled
Cases (2003)
1187 (59.3%)
706 (35.2%)
110 (5.5%)
3080 (76.9%)
926 (23.1%)
3.74E−10
1.38 (1.25-1.53) c
Controls (1968)
974 (49.9%)
817 (41.8%)
162 (8.3%)
2763 (70.8%)
1141 (29.2%)
Population
TT
CT
CC
Chi square
P-Value
Odds ratio (CI)
Allele T
Allele C
P-Value
Odds ratio (CI)
rs17266594
Scandinavian SLE
Cases (511)
296 (57.9%)
189 (37.0%)
26 (5.1)
9.4399
0.0089
TT: 2.17 (1.28-3.66)
781 (76.4%)
241 (23.6%)
0.0036
1.36 (1.10-1.68)
Controls (416)
210 (50.5%)
166 (39.9%)
40 (9.6%)
CT: 1.75 (1.03-2.99)
586 (70.4%)
246 (29.6%)
Argentina SLE
Cases (274)
188 (68.6%)
77 (28.1%)
9 (3.3%)
14.1697
8.38E−04
TT: 3.26 (1.51-7.06)
453 (82.7%)
95 (17.3%)
1.06E−04
1.73 (1.30-2.31)
Controls (346)
192 (55.5%)
124 (35.8%)
30 (8.7%)
CT: 2.07 (0.93-4.59)
508 (73.4%)
184 (26.6%)
Germany SLE
Cases (241)
132 (54.8%)
98 (40.7%)
11 (4.6%)
7.7164
0.0211
TT: 2.46 (1.19-5.09)
362 (75.1%)
120 (24.9%)
0.0080
1.43 (1.09-1.87)
Controls (335)
151 (45.1%)
153 (45.7%)
31 (9.3%)
CT: 1.81 (0.87-3.76)
455 (67.9%)
215 (32.1%)
Italy SLE
Cases (231)
130 (56.3%)
87 (37.7%)
14 (6.1%)
10.1706
0.0062
TT: 2.42 (1.19-4.93)
347 (75.1%)
115 (24.9%)
0.0016
1.59 (1.18-2.14)
Controls (219)
92 (42.0%)
103 (47.0%)
24 (11.0%)
CT: 1.45 (0.71-2.97)
287 (65.5%)
161 (34.5%)
Spain SLE
Cases (678)
404 (59.6%)
231 (34.1%)
43 (6.3%)
14.8617
5.93E−04
TT: 1.04 (0.62-1.76)
1039 (76.6%)
317 (23.4%)
0.010
1.29 (1.06-1.56)
Controls (458)
225 (49.1%)
208 (45.4%)
25 (5.5%)
CT: 0.65 (0.38-1.09)
658 (71.8%)
258 (28.2%)
Pooled
Cases (1856)
1102 (59.4%)
655 (35.3%)
99 (5.3%)
2859 (77.0%)
853 (23.0%)
4.74E−11
1.42 (1.28-1.58) c
Controls (1774)
870 (49.0%)
754 (42.5%)
150 (8.5%)
2494 (70.3%)
1054 (29.7%)
Population
TG/TG
TG/other
other/other
Chi square
P-Value
TG
other
P-Value
Odds ratio (CI)
Haplotype
Scandinavian SLE
Cases (509)
293 (57.6%)
190 (37.3%)
26 (5.1%)
4.6600
0.0973
776 (76.3%)
242 (23.8%)
0.22738
1.14 (0.91-1.43)
Controls (365)
205 (56.2%)
128 (35.1%)
32 (8.8%)
538 (73.8%)
192 (26.4%)
Argentina SLE
Cases (260)
187 (71.9%)
55 (25.0%)
8 (3.1%)
11.8483
0.0027
439 (84.4%)
81 (15.6%)
0.00032
1.72 (1.27-2.36)
Controls (317)
189 (59.6%)
103 (32.5%)
25 (7.9%)
481 (75.9%)
153 (24.1%)
Germany SLE
Cases (237)
131 (55.3%)
94 (39.7%)
12 (5.1%)
6.6099
0.0367
356 (75.1%)
118 (24.9%)
0.01228
1.40 (1.07-1.85)
Controls (331)
151 (45.6%)
150 (45.3%)
30 (9.1%)
452 (68.3%)
210 (31.7%)
Italy SLE
Cases (230)
130 (56.5%)
87 (37.8%)
13 (6.7%)
9.4922
0.0067
347 (75.4%)
113 (24.6%)
0.00225
1.57 (1.16-2.13)
Controls (214)
92 (43.0%)
99 (46.3%)
23 (10.7%)
283 (66.1%)
145 (33.9%)
Spain SLE
Cases (589)
324 (55.0%)
217 (36.8%)
48 (8.1%)
5.4954
0.0641
865 (73.4%)
313 (26.6%
0.43109
1.09 (0.88-1.34)
Controls (374)
185 (49.7%)
165 (44.1%)
23 (6.1%)
537 (71.8%)
211 (28.2%)
Pooled
Cases (1825)
1065 (58.4%)
653 (35.8%)
107 (5.9%)
2783 (76.2%)
867 (23.8%)
4.75E−06
1.30 (1.16-1.45)
Controls (1601)
823 (51.4%)
545 (40.3%)
133 (6.3%)
2291 (71.5%)
911 (28.5%)
a Genotypic odds ratio calculated using homozygosity for the protective allele as reference with OR = 1
b Mantel-Haenzel Chi square using fixed effects
c Using the Robins, Breslow and Greenland method
SUPPLEMENTARY TABLE 2
SNP rs number
MB Build 36
Location in BANK1
rs7675129
102894046
intergenic
rs11726012
102925041
promoter
rs11097755
102928331
5′UTR
rs4522865
102934911
intronic
rs4496585
102937309
intronic
rs4572885
102954536
intronic
rs10516487
102970099
exon coding (NS)*
rs10516486
102970299
exon 2 (synonymous)
rs17200824
102971612
intronic
rs6849308
102995106
intronic
rs10516482
102999193
intronic
rs10516483
103010928
intronic
rs10516484
103011108
intronic
rs4493533
103039707
intronic
rs3733197
103058310
exon coding NS
rs2631271
103133419
intronic
rs2850390
103163019
intronic
rs2631265
103164099
intronic
rs2631267
103167495
intronic
rs2631268
103167753
intronic
rs10516491
103171889
intronic
rs1872701
103172704
intronic
rs2850393
103174239
intronic
rs2850396
103187471
intronic
rs10516490
103193084
intronic
rs10516489
103193382
intronic
rs10516488
103196800
intronic
rs1395306
103204873
intronic
*NS: non-synonymous substitution
SUPPLEMENTARY TABLE 3
Genotypic and Allelic Association of rs3733197 in five sets of
SLE cases and controls and joint analysis with Mantel-Haenzel test.
Population
GG
GA
AA
Chi square
P-Value
Odds ratio (CI) a
Scandinavian SLE
Cases (419)
167 (39.9%)
192 (45.8%)
60 (14.3%)
1.2365
0.5389
GG: 1.04 (0.69-1.58)
Controls (444)
163 (36.7%)
220 (49.6%)
61 (13.7%)
GA: 0.89 (0.59-1.33)
Argentina SLE
Cases (287)
177 (61.7%)
97 (33.8%)
13 (4.5%)
9.6496
0.0080
GG: 2.36 (1.20-4.66)
Controls (363)
184 (50.7%)
147 (40.5%)
32 (8.8%)
GA: 1.62 (0.81-3.25)
Germany SLE
Cases (272)
128 (47.1%)
112 (41.2%)
32 (11.8%)
4.1431
0.1260
GG: 1.65 (1.01-2.69)
Controls (362)
148 (40.9%)
153 (42.3%)
61 (16.9%)
GA: 1.40 (0.85-2.28)
Italy SLE
Cases (253)
131 (51.8%)
102 (40.3%)
20 (7.9%)
8.2595
0.0161
GG: 1.74 (0.92-3.29)
Controls (251)
98 (39.0%)
127 (50.6%)
26 (10.4%)
GA: 1.04 (0.55-1.98)
Spain SLE
Cases (588)
307 (52.2%)
234 (39.8%)
47 (8.0%)
3.4580
0.1775
GG: 1.14 (0.72-1.82)
Controls (455)
212 (46.6%)
206 (45.3%)
37 (8.1%)
GA: 0.89 (0.56-1.43)
Pooled
Cases (1819)
910 (50.0%)
737 (40.5%)
172 (9.5%)
Controls (1875)
805 (42.9%)
853 (45.5%)
217 (11.6%)
Population
Allele G
Allele A
Chi square
P-Value
Odds ratio (CI)
Scandinavian SLE
Cases (419)
526 (62.8%)
312 (37.2%)
0.301
0.5832
1.06 (0.87-1.29)
Controls (444)
546 (61.5%)
342 (38.5%)
Argentina SLE
Cases (287)
451 (78.6%)
123 (21.4%)
9.787
0.0018
1.15 (0.95-1.40)
Controls (363)
515 (70.9%)
211 (29.1%)
Germany SLE
Cases (272)
368 (67.6%)
176 (32.4%)
4.297
0.0382
1.28 (1.00-1.63)
Controls (362)
449 (62.0%)
275 (38.0%)
Italy SLE
Cases (253)
364 (71.9%)
142 (28.1%)
6.696
0.0097
1.42 (1.08-1.87)
Controls (251)
323 (64.3%)
179 (35.7%)
Spain SLE
Cases (588)
977 (72.1%)
379 (27.9%)
2.099
0.1474
1.50 (1.15-1.96)
Controls (455)
630 (69.2%)
280 (30.8%)
Pooled
Cases (1819)
2686 (70.4%)
1132 (29.6%)
16.5763
4.67E−05
1.23 (1.11-1.36)
Controls (1875)
2463 (65.7%)
1287 (34.3%)
SUPPLEMENTARY TABLE 4 Primer sequences Gene/gene SEQ ID SEQ ID fragment/isoform Forward NO NO Reverse hBANK cDNA CACC TCAACCGCCACAA 7 ATAATAACCTTCTTTAATGA 8 amplification TGCTGCCAGCA TCTTTCTTGC Total BANK1 qRT-PCR AGAGGAAACTACACCTT 9 GATGAGTTCTTCCTGACCA 10 ACATAGCTC TCAG Total full-length TCAAAGCAGATGGGAGA 11 isoforms TCTCAAC Delta2 isoform CAGCGCCCCCAGATTCT 12 GAAG Exon1A full-length CAGCGCCCCCAGGAAAT 13 isoform ACA Alternative exon1 full- GCCTATTCTTTGTTTTGG 14 length isoform AAATACA Common reverse primer for all isoforms for qRT-PCR CACATGGAATTTCAGTGGG 15 AAGCAC Common reverse primer for gel-analysis ATCACAGTAGACATTGACA 16 TGGAC
For Genomic Sequencing:
Gene/gene
SEQ ID
SEQ ID
fragment/isoform
Forward
NO
Reverse
NO
promoter, exon 1A
TTGGAGAGGGTATTTA
17
AAGCAGGGCTACCAATT
18
and 5′-part of
GAGCCATA
CACCAG
intron 1
Alternative exon1B
CTATGATACTGGAAAT
19
AGCATATGACCAGCTGA
20
ACTGTCAGT
TCAG
Exon2
TTGATTTACTATGAAA
21
TTACATAAGAAACCAGC
22
ATATCAAGC
TTCCAG
mouse BANK1 Cdna
ACCTCCCGCAATGCT
23
ACATGGAATTTCCCCAG
24
TCCTGT
GAAGCAC
REFERENCE LIST
1. Sherer, Y., Gorstein, A., Fritzler, M. J. & Shoenfeld, Y. (2004) Semin Arthritis Rheum 34, 501-37.
2. Former K, L. M., Guedj M, Dauvillier J and Wojcik J. Hum Hered , In Press.
3. Yokoyama, K., Su Ih, I. H., Tezuka, T., Yasuda, T., Mikoshiba, K., Tarakhovsky, A. & Yamamoto, T. (2002) Embo J 21, 83-92.
4. Aiba, Y., Yamazaki, T., Okada, T., Gotch, K., Sanjo, H., Ogata, M. & Kurosaki, T. (2006) Immunity 24, 259-68.
5. Burge, C. B., Tuschl, T. & Sharp, P. A (1999), ed. Gesteland, R. F., Cech, T. R. & Atkins, J. F (Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.), pp. 525-560.
6. Jordan, M. S., Singer, A. L. & Koretzky, G. A. (2003) Nat Immunol 4, 110-6.
7. Kurosaki, T. (2002) Nat Rev Immunol 2, 354-63.
8. Okada, T., Maeda, A., Iwamatsu, A., Gotoh, K. & Kurosaki, T. (2000) Immunity 13, 817-27.
9. Patterson, R. L., Boehning, D. & Snyder, S. H. (2004) Annu Rev Biochem 73, 437-65.
10. Mohler, P. J., Schott, J. J., Gramolini, A. O., Dilly, K. W., Guatimosim, S., duBell, W. H., Song, L. S., Haurogne, K., Kyndt, F., Ali, M. E., Rogers, T. B., Lederer, W. J., Escande, D., Le Marec, H. & Bennett, V. (2003) Nature 421, 634-9.
11. Blom, N., Gammeltoft, S. & Brunak, S. (1999) J Mol Biol 294, 1351-62.
12. Anolik, J., Sanz, I. & Looney, R. J. (2003) Curr Rheumatol Rep 5, 350-6.
13. Liossis, S. N., Kovacs, B., Dennis, G., Kammer, G. M. & Tsokos, G. C. (1996) J Clin Invest 98, 2549-57.
14. Huck, S., Le Corre, R., Youinou, P. & Zouali, M. (2001) Autoimmunity 33, 213-24.
15. Liossis, S. N., Solomou, E. E., Dimopoulos, M. A., Panayiotidis, P., Mavrikakis, M. M. & Sfikakis, P. P. (2001) J Investig Med 49, 157-65.
16. Hibbs, M. L., Harder, K. W., Armes, J., Kountouri, N., Quilici, C., Casagranda, F., Dunn, A. R. & Tarlinton, D. M. (2002) J Exp Med 196, 1593-604.
17. Flores-Borja, F., Kabouridis, P. S., Jury, E. C., Isenberg, D. A. & Mageed, R. A. (2005) Arthritis Rheum 52, 3955-65.
18. Cornall, R. J., Oyster, J. G., Hibbs, M. L., Dunn, A. R., Otipoby, K. L., Clark, E. A. & Goodnow, C. C. (1998) Immunity 8, 497-508.
19. Kozyrev, S. V., Lewén, S., Ling a Reddy, M. V. P., Pons-Estel, B. A., The Argentine Collaborative Group, Witte, T., The German Collaborative Group, Junker, P., Laustrup, H., Gutiérrez, C., Suárez, A., González-Escribano, M. F., Martin, J., The Spanish Collaborative Group and Alarcón-Riquelme, M. E. (2007) Arthritis and Rheumatism 56, 1234-41.
20. Tan, E. M., Cohen, A. S., Fries, J. F., Masi, A. T., McShane, D. J., Rothfield, N. F., Schaller, J. G., Talal, N. & Winchester, R. J. (1982) Arthritis Rheum 25, 1271-7.
21. Guedj, M., Wojcik, J., Della-Chiesa, E., Nuel, G. & Forner, K. (2006) Hum Hered 61, 210-21.
22. Stephens, M. & Donnelly, P. (2003) Am J Hum Genet 73, 1162-9.
23. Stephens, M., Smith, N. J. & Donnelly, P. (2001) Am J Hum Genet 68, 978-89.
24. Dudbridge, F. (2003) Genet Epidemiol 25, 115-21.
25. Freeman, W. M. and S. E. Hemby (2004). “Proteomics for protein expression profiling in neuroscience.” Neurochem Res 29(6): 1065-81.
26. Gut, I. G. (2004). “DNA analysis by MALDI-TOF mass spectrometry.” Hum Mutat 23(5): 437-41.
Shi, M. M. (2001). “Enabling large-scale pharmacogenetic studies by high-throughput mutation detection and genotyping technologies.” Clin Chem 47(2): 164-72.
28. Zhu, H. and M. Snyder (2003). “Protein chip technology.” Curr Opin Chem Biol 7(1): 55-63.
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The present invention relates to a new splice variant of BANK1, the use of SNPs in BANK1 for diagnostics and the use of antagonists to modulate BANK1 and/or the BANK1 pathway.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional applications Serial No. 60/169,855, filed Dec. 9, 1999; Serial No. 60/170,380, filed Dec. 13, 1999; Serial No. 60/178,010, filed Jan. 24, 2000; and Serial No. 60/178,042, filed Jan. 24, 2000.
TECHNICAL FIELD
[0002] This invention relates to structured packing for an exchange column, and, particularly, for a mass transfer column such as a cryogenic rectification column.
BACKGROUND OF THE INVENTION
[0003] Various types of exchange columns have been known in which a gas and a liquid come into contact with one another, generally in countercurrent flow. It is common to use packing elements formed of corrugated sheets or plates which contact one another and are disposed in parallel to the column axis to encourage contact between the liquid and gas. In such cases, the folds or corrugations of the plates are disposed at an angle to the column axis. Additionally, improvements have been made to structured packing to decrease the gas flow resistance in the lower region of a structured packing section, thus increasing the packing capacity. More specifically, the pressure drop associated with the gas or vapor entry into the structured packing section is made to be less than the pressure drop which would be experienced if the configuration of the structured packing in the lower region had the same configuration as in the upper portion of the structured packing section. Such improvements are described in U.S. Pat. No. 5,632,934. This patent contemplates a bulk region and a base region. The patent discloses the base region having various configurations to reduce the pressure drop therein.
[0004] A packing structure is needed which has further increased performance characteristics.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is an object of the present invention to provide a packing section whose geometry can be varied in a base region, a top region, or both, to accomplish various performance requirements of a column.
[0006] A further object of the present invention is to provide a packing section wherein surface texturing is selectively used throughout the packing section to provide the desired performance of the column.
[0007] Accordingly, the present invention provides for a packing section, including a plurality of vertically oriented, diagonally-cross-corrugated packing sheets defining a section height. The section height has a base region, a bulk region, and a top region. The base region has a first particular geometry different from the geometry of the bulk region. The top region has a second particular geometry different from the geometry of the bulk region, and different from the first geometry of the base region.
[0008] The invention further includes a packing section having a plurality of vertically oriented, diagonally cross-corrugated packing sheets defining a section height. The section includes a base region, a bulk region, and a top region. The bulk region includes surface texturing. Further, at least a portion of at least one of the base region and the top region does not have surface texturing.
[0009] The invention further provides for a packing section having a plurality of vertically oriented, diagonally cross-corrugated packing sheets defining a section height. The section has a base region, a bulk region, and a top region. The bulk region includes generally horizontal fluting. Further, at least a portion of at least one of the base region and the top region includes generally vertical fluting.
[0010] Additional objects, advantages, and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the accompanying drawings, which form apart of this specification, and are to be read in conjunction therewith, and in which like reference numerals are used to indicate like parts in the various views:
[0012] [0012]FIG. 1 is a top perspective view of various packing sections disposed one on top of one another as if positioned in a column;
[0013] [0013]FIG. 2 a is a top plan view of a single packing section;
[0014] [0014]FIG. 2 b is a top plan view of a cross section through a column showing various packing bricks making up a packing section layer;
[0015] [0015]FIG. 3 is a top perspective view of a packing section;
[0016] [0016]FIG. 4 is a top perspective view of two structured packing sheets embodying a first embodiment of the present invention;
[0017] [0017]FIG. 5 is a view similar to FIG. 4, but showing a second embodiment of the present invention;
[0018] [0018]FIG. 6 is a top perspective view of a single packing sheet showing a third embodiment of the present invention;
[0019] [0019]FIG. 7 is a front elevational view of a single packing sheet showing a fourth embodiment of the present invention;
[0020] [0020]FIG. 8 is a front elevational view of a single packing sheet showing a fifth embodiment of the present invention;
[0021] [0021]FIG. 9 is a front elevational view of a single packing sheet showing a sixth embodiment of the present invention;
[0022] [0022]FIG. 10 is a top perspective view of a single packing sheet showing a seventh embodiment of the present invention;
[0023] [0023]FIG. 11 is a front elevational view of a single packing sheet showing an eighth embodiment of the present invention;
[0024] [0024]FIG. 12 is a front elevational view of a single packing sheet showing a ninth embodiment of the present invention;
[0025] [0025]FIG. 13 is a front elevational view of a single packing sheet showing a tenth embodiment of the present invention; and
[0026] [0026]FIG. 14 is a front elevational view of a single packing sheet showing an eleventh embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The present invention is directed to an improvement of U.S. Pat. No. 5,632,934, the disclosure of which is incorporated herein by reference. More specifically, U.S. Pat. No. 5,632,934 is directed to varying the configuration in the base region of a packing section, and discloses various different configurations in the base region to decrease the gas pressure drop in the base region. For instance, the patent discloses reducing gas resistance in the base region by having: (1) staggered sheets in the base region, (2) flat portions in the base region, (3) reduced cross section corrugations in the base regions, (4) steeper corrugations in the base region, (5) orifices in the base region, (6) sawtooth configurations in the base region, and (7) louvers in the base region. The present invention improves the performance of this known packing, as will be more fully described below.
[0028] With reference to FIG. 1, structured packing includes vertically oriented sheets with corrugations at an angle to the vertical axis of a column. Sheets, are arranged such that the corrugation direction of adjacent sheets is reversed to one another. The packing is installed in the column as layers or sections “S”. Adjacent sections S are rotated around a vertical axis to enhance mixing, as is shown in FIG. 1.
[0029] In smaller columns, each layer may be comprised of a single section or brick of packing formed by affixing individual sheets together, as is shown in FIG. 2 a. In larger columns, each packing section S may be made from several bricks “B” that fit together to fill a cross section of the containing vessel, as is shown in FIG. 2 b. The complete packing column comprises multiple sections S of packing, the number of sections S being set by the height of packing required to perform the separation.
[0030] With reference to FIG. 3, one packing section S is shown. Packing section S has a height “H”, a top region “T”, a bulk region “U” and a base region “L”. Typically, the height of the base region L and the height of top region T each would be about 5% to 10% of the section height H, but, depending upon a number of considerations and particular performance characteristics of the column, could each be smaller or each be as large as one-third of the section height H. Region L and region T need not be the same height, and could significantly vary depending upon the desired performance characteristics of the column.
[0031] It has been found preferable to have the height of region L and region T be dependent upon the specific surface area of the packing. More specifically, the specific surface area of a packing is a function of the crimp size of the sheets. The smaller the crimp size, generally the larger the specific surface area. Specific surface area is usually defined as the surface area of the sheets in a packing section (in m 2 ) divided by the volume of the packing section (in m 3 ). It has been found that the larger the specific surface area for a given section height H, the smaller the height of regions L and T need to be. Table 1 below demonstrates this correlation for a section height H about 8 in. to 11 in.
TABLE 1 Specific Surface Height of Region T Height of Region L Area (m 2 /m 3 ) (in.) (in.) 750-1200 (m 2 /m 3 ) ¼ in.-¾ in. ¼ in.-¾ in. 350-750 (m 2 /m 3 ) ½ in.-1 in. ½ in.-1 in 100-350 (m 2 /m 3 ) ¾ in.-2 in. ¾ in.-2 in.
[0032] With reference to FIG. 4, one embodiment of the present invention is shown. In this embodiment, two adjacent packing sheets 20 are shown. The bulk region U of the sheets 20 have angled corrugations, and adjacent sheets 20 extend in different directions. Top region T of each sheet 20 includes generally vertical corrugations 22 . More specifically, these corrugations can be of the same height and cross section as the corrugations found in bulk region U; however, they are angled more vertically than the corrugations in bulk region U. The steeper corrugations 22 are shown in FIG. 4 as being vertical; however, they need not necessarily be vertical. They may have, instead, a closer to vertical angle than the corrugations found in bulk region U. Further, the transition from the corrugations in bulk region U to vertical corrugations 22 is shown as abrupt. A gradual transition is also contemplated. With still further reference to FIG. 4, sheets 20 are shown as having flat sections 24 in base region L. More specifically, there are generally no corrugations at all in base region L. The present invention of having different geometries in top region T and base region L allows further increased performance of a packing section. More specifically, the steeper corrugations in top region T allow easier transitioning of vapor into the above packing element, while flat section 24 in base region L helps decrease vapor pressure drop in base region L and in the transition region.
[0033] A further embodiment is shown in FIG. 5, wherein sheets 20 have the same vertical corrugations 22 in top region T; but, however, have reduced cross section corrugations 26 in base region L. More specifically, corrugations 26 are smaller in height than the corrugations found in bulk region U. Again, this difference in geometry recognizes the needs of the different regions of the packing section to accomplish transition and pressure reduction.
[0034] Although the above two embodiments are disclosed, as is apparent, it may be desirable to have other different geometries in the top region T and the lower region L. Such geometries can be as those disclosed in U.S. Pat. No. 5,632,934.
[0035] It is known to utilize surface texturing on packing sheets 20 . The term “surface texturing”, as used herein, is to be understood as denoting any roughening, slitting, stamping and/or impressing of the sheet surface. Examples of surface texturing include, but are not limited to, grooving (“fluting”), impression of a pattern, for example, a herringbone or waffle pattern, or small deformed slits. An example of “fluting” can be found in U.S. Pat. No. 4,296,050, the disclosure of which is incorporated herein by reference. This patent discloses fine fluting in the form of grooves. The fine fluting results in spreading of liquid over the sheet surfaces as a result of capillary action.
[0036] With reference to FIG. 6, a further embodiment of the present invention is shown. More specifically, in this embodiment, a base region L of a sheet 20 is shown, wherein the base region L does not have the surface texturing shown in the bulk region U and the top region T. The embodiment shown in FIG. 6 discloses the surface texturing in region U and region T as the fine fluting of a packing sheet. The fine fluting extends generally horizontally and results in the spreading of liquid across the face of the sheet. Although the “surface texturing” shown is fine fluting, any other surface texturing could also be used. In the base region L, there may not be a need to have the liquid move across the packing, but instead to have the liquid move quickly off the packing sheet to the packing section below. Therefore, the absence of any surface texturing in base region L can accomplish this. Additionally, top region T can also be void of surface texturing to accomplish the desired performance characteristics of the column. Therefore, a sheet is contemplated where both top region T and base region L, or only base region L or only top region T is devoid of surface texturing.
[0037] With reference to FIG. 7, a further embodiment of the present invention is shown. More specifically, a sheet 20 is shown having a bulk region U with fine flutings extending generally horizontal to the axis of the column. Top region T and bottom region L each have vertical corrugations 22 . However, top region T and base region L do not have any surface texturing.
[0038] With reference to FIG. 8, a further embodiment is shown which is similar to FIG. 7; however, top region T, while having vertical corrugations 22 , does not have fine fluting. However, base region L does have fine fluting in addition to vertical corrugations 22 .
[0039] [0039]FIG. 9 is a further variation of FIGS. 7 and 8, wherein top region T has fine fluting and vertical corrugations 22 while bottom region L does not have fine fluting, but does have vertical corrugations 22 .
[0040] As discussed above, fine fluting has been shown extending generally horizontal to the axis of the column. As is apparent, any other surface texturing could be used.
[0041] It has been found that it may be desirable to enhance the removal of liquid from a section or a sheet to have generally vertical fine fluting in at least a portion of base region L or top region T. With reference to FIG. 10, a sheet 20 is shown, wherein there are generally horizontal fine flutings in the bulk region U and top region T; however, there is vertical fine fluting in base region L. As is apparent, there could be other variations wherein the generally vertical fine fluting is utilized in both top region T and bottom region L, or just in the top region T and not in the base region L.
[0042] With reference to FIG. 11, a still further embodiment is shown wherein top region T and base region L of a sheet 20 each have vertical corrugations 22 . Additionally, each of top region T and base region L have generally vertical fine fluting, as opposed to the generally horizontal fine fluting found in base region U.
[0043] With reference to FIG. 12, another embodiment is shown wherein a sheet 20 includes top region T and base region L with vertical corrugations 22 . Additionally, top region T has generally vertical fine fluting, bulk region U has generally horizontal fine fluting, and base region L has no fine fluting at all.
[0044] A still further embodiment is shown in FIG. 13, again wherein both top region T and base region L have vertical corrugations 22 but wherein top region T has no fine fluting, bulk region U has generally horizontal fine fluting, and bottom region L has generally vertical fine fluting.
[0045] Although the vertical fluting in the drawings are shown as vertical, any fluting that extends at a steeper angle than the generally horizontal fluting could be used to possibly enhance the performance characteristics of the column. Additionally, the generally horizontal fine fluting in bulk region U could be any other suitable surface texturing.
[0046] As is apparent, various surface texturing combinations can be utilized in top region T and bottom region L, with the different geometries disclosed in U.S. Pat. No. 5,632,934. For instance, any of the generally horizontal fine fluting and vertical fluting combinations disclosed above could be utilized in conjunction with the flat sheet 24 geometries, or reduced corrugation height geometry 26 discussed above.
[0047] Further, with respect to all the above embodiments, in addition to surface texturing, a sheet 20 could have a plurality of discrete apertures disposed throughout. Such apertures could be as disclosed in U.S. Pat. No. 4,296,050. If such apertures are disposed in a sheet 20 , it may be desirable to have top region T or bottom region L, or both, be devoid of such apertures in addition to being devoid of surface texturing.
[0048] The present invention may be used in any distillation, absorption, or stripping process, which may employ structured packing. Examples, but not limitations of the structured packing include, oil fractionations, hydrocarbon separations, alcohol distillations, and cryogenic rectification such as cryogenic air separation systems.
[0049] From the foregoing, it will be seen that this invention is one well-adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
[0050] For example, as shown in FIG. 14, sheet 20 is shown as having a bulk region U with fine fluting extending generally horizontal to the axis of the column. Bulk region U also has apertures 28 disposed throughout. Top region T and bottom region L each have vertical corrugations 22 . However, top region T and base region L do not have any surface texturing, nor do they have any apertures 28 . Thus, the surfaces of top region T and base region L are smooth.
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A packing section includes a plurality of vertically oriented, diagonally cross-corrugated packing sheets defining a section height. The section height has a base region, a bulk region, and a top region. The base region has a first particular geometry different from the geometry of the bulk region. The top region has a second particular geometry different from the geometry of the bulk region, and different from the first particular geometry of the base region.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of International Application No. PCT/EP2010/069351, filed Dec. 10, 2010, which application claims priority to U.S. Provisional Application No. 61/289,250, filed Dec. 22, 2009 and to German Application No. 10 2009 059 950.9, filed Dec. 22, 2009, which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
The technical field relates to an apparatus for adjusting and locking a movable control surface, to a control surface unit and to the use of an apparatus for adjusting and locking a movable control surface. The technical field also relates to an advantageous design of wind-tunnel aircraft models.
BACKGROUND
In a wind tunnel, for the purpose of determining aerodynamic parameters, aircraft models are used which are designed to reflect the prototype as accurately as possible and which, depending on the type and purpose of measuring, in measuring experiments can also comprise deflected control surfaces. Normally, for this purpose, control surfaces with deflection angles that are set so as to be fixed are used, which control surfaces need to be exchanged after every measuring process. This requires entering the wind tunnel, manually exchanging the control surfaces on the aircraft model, and subsequently carrying out the next measuring process. Because of the significant costs associated with operating the wind tunnel, in the case of extended measuring campaigns with many different control surface angles this is not a particularly advantageous solution.
Furthermore, it is known, in some cases, to use adjustment devices for moving control surfaces, which adjustment devices are arranged outside the aircraft model and, by way of rods, can move control surfaces in a remotely-controlled manner. Because of the possibility of influencing the airflow this is not particularly advantageous.
In DE 10 2008 003 543 A1 and in US 2009 0179109 A1 a system and method for adjusting and locking a control surface movably arranged on a wind-tunnel aircraft model is disclosed. The system comprises a drive arrangement for driving the control surface, and a locking arrangement. The control surface is movable by way of a connecting rod, and can be locked in a predetermined graduated position by means of a toothed locking arrangement. DE 10 2005 040 441 A1 shows a linear actuator, especially for remote control of adjustable components on wind tunnel models, having a housing, gear motor and a threaded spindle. The threaded spindle is connected to the gear motor with a chain drive. DE 102 08 258 A1 shows an apparatus for providing an adjustable flow profile, especially for a flow body positioned in a cryogenic surrounding, having a linear actuator and two coupled cranks, and DE 696 24 060 T2 shows an electric actuator having an actuator housing with a plurality of elongated wedges arranged in am axial direction.
In view of the foregoing, at least one object is to provide an apparatus for adjusting a control surface that supports as compact as possible a design for integration in an aircraft model, while at the same time making it possible to achieve precise, repeatable deflection of control surfaces in a non-incremental manner, which deflection remains the same even if subjected to an aerodynamic flow. In addition, other objects, desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
An apparatus is provided for adjusting and locking a movable control surface comprises at least one rotatably held spindle, at least one adjustment body, at least one linear guide, at least one drive unit, at least one linear positioning encoder and at least one control unit. The adjustment body with the linear guide is slidably guided along a first movement axis; the spindle is connected to the adjustment body for moving the adjustment body along the movement axis; the adjustment body is designed to be connected to a mount of a control surface; the linear positioning encoder and the drive unit are connected to the control unit; and the control unit is designed to adjust a predetermined actuating position of the adjustment body by rotation of the spindle with the drive unit and by comparing an actual position, detected by the linear positioning encoder, of the adjustment body with the predetermined actuating position.
The combination of the rotatably held spindle, the adjustment body and the linear guide allows infinitely variable linear movement, as is common in mechanical linear actuators. With the additional control unit, which by way of a signal connection or data connection can receive a value relating to a predetermined actuating position, a drive unit the spindle can be rotated so that the adjustment body is moved in the linear guide. As soon as the control unit, by way of the linear positioning encoder, detects the actual position that correlates to the predetermined actuating position, the drive unit is stopped so that the control surface, for example, remains in a predetermined angle position.
In order to achieve a very precise actuating position, whose accuracy essentially depends on the accuracy of the linear positioning encoder and on the play in the drive train, the control unit may achieve different adjustment speeds of the drive unit by way of suitable control of the drive unit. Shortly before reaching the predetermined actuating position the adjustment speed may be significantly reduced so that the inertia of the drive unit and of the adjustment body as well as of the driven control surface and of the components of the drive train is reduced, and the predetermined actuating position is finally reached at reduced speed. This may save readjustment by reverse rotation of the drive unit.
In the simplest case the drive unit can be a motor that may, for example, be designed as a brushless electric motor. Depending on the size and design of the electric motor, in order to reduce the rotary speed and in order to increase torque, it may be sensible to arrange a gear arrangement between the motor and the spindle. In order to achieve as compact a design unit as possible it makes sense to design the gear arrangement as a planetary gear arrangement that may be designed so as to be point-symmetrical to the longitudinal axis of the electric motor and that ideally is accommodated in a housing directly with the motor. This provides a space-saving design of the apparatus.
According to an embodiment, the spindle is designed so as to be self-locking and free of play. In this manner a hysteresis effect, which manifests itself in inaccurate positioning, may be avoidable. As a result of the self-locking design of the spindle, the adjusted position of the control surface can be maintained even if the control surface is subjected to loads during aerodynamic experiments, because mechanically coupling the control surface to the spindle does not make it possible for the spindle to rotate when a force acts on said spindle. In this context it should be mentioned that, of course, the connection between a control surface mount that is to be driven and the adjustment body should also be designed so as to be free of play, and consequently inaccurate positioning can be entirely avoided.
According to an embodiment, the adjustment body comprises a spindle nut with a spindle nut thread that corresponds to a spindle thread of the spindle and that comprises a recess that is suitable for receiving the spindle nut in a positive-locking and non-rotational manner by sliding in. Consequently the adjustment body can be produced separately from the spindle nut, and if required the spindle and the spindle nut can be exchanged very easily without there being any need to effect modifications on the entire apparatus.
According to an embodiment, the adjustment body comprises connecting means for connection to an adjustment lever. The use of a connection on the adjustment body supports direct coupling to a control surface mount. The adjustment lever can comprise a very slim design so that the apparatus can more easily be integrated in the aircraft model. The connection may, for example, be a suitably formed recess or a cutout on a delimitation edge for receiving the adjustment lever; at the same time it may also be an angle mount or the like. All the connections preferably define a hinge line around which the adjustment lever can be hinged. This hinge line preferably extends so as to be perpendicular to the movement axis of the adjustment body.
According to an embodiment of the apparatus, the linear guide has been implemented as a body with a movement-axis-symmetrical recess for guiding the adjustment body. By forming a body with such a recess, it is possible both to achieve a design of the apparatus, which design is as slender as desired, and at the same time also to achieve a very simple design. The adjustment body and the recess can be equipped with a corresponding sliding fit that makes it possible for the adjustment body to move to the greatest extent possible free of play.
According to an embodiment, the adjustment body is coupled to a limit switching device that is connected to the control unit. The limit switching device is designed, when an extreme position of the adjustment body is detected, to avoid an adjustment movement direction that would result in exceeding the corresponding extreme position by preventing movement in the corresponding adjustment movement direction. Overloading the drive unit and the adjustment lever can be prevented by avoiding hard mechanical end stops. Preventing continuous movement in a critical direction in terms of an extreme position reached nevertheless makes it possible to move back into a position opposite the blocked movement direction. The control unit would preferably be designed in such a manner that after the extreme position has been left, both movement directions are available again.
According to an embodiment, the apparatus comprises two limit switching devices that are designed as two photoelectric barriers that are spaced apart from each other. A connecting line between the two photoelectric barriers extends parallel to the movement axis. The adjustment body is coupled to a disrupting profile which when the adjustment body moves can be guided through the two photoelectric barriers. The use of photoelectric barriers and of a disrupting profile that can be moved into the photoelectric barriers avoids the use of micro switches or other mechanical design units whose function may be impaired with frequent use or with extended lack of use. The photoelectric barriers are not subject to wear, and thus provide a very favorable and reliable option of a limit switching device.
Furthermore, a control surface unit, in which the drive unit is arranged on the linear guide within which the spindle for moving the adjustment body extends, and furthermore comprises an adjustment lever and a control surface hingeably held on the linear guide, which control surface is arranged on the adjustment body by way of a control surface mount with the adjustment lever. The control surface unit forms a compact unit which viewed in isolation merely needs to be connected, by way of an electrical connection and a data connection, for example to a control desk, a terminal or the like, in order to adjust the control surface angle when required. Furthermore, the use of such an apparatus is provided for adjusting and locking a movable control surface on an aircraft model for a wind tunnel.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics, advantages and application options are disclosed in the following detailed description in conjunction with the figures. All the described and/or illustrated characteristics per se and in any combination form the embodiments, even irrespective of their composition. Furthermore, identical or similar objects in the figures have the same reference characters, and:
FIG. 1 shows an isometric view of the apparatus with a control surface arranged thereon;
FIG. 2 shows a lateral section view of the apparatus with a control surface arranged thereon;
FIG. 3 shows an exploded view of the apparatus; and
FIG. 4 shows an apparatus, which apparatus has been integrated in an aircraft model.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description.
FIG. 1 shows an isometric view of the apparatus 2 , which apparatus 2 comprises a drive unit 4 with an electric motor 6 , a gear arrangement 8 and two limit switching devices 10 and 12 arranged thereon. The electric motor 6 is arranged on a gear arrangement 8 that has the same external diameter, which gear arrangement 8 in turn is mounted on a cover 14 of a gear arrangement housing 16 , with the aforesaid following on from a linear guide 18 . The latter in turn comprises two connection 20 that are designed in the form of angle mounts formed in a single piece on the linear guide 18 . At said location a hinge line 48 is formed with a control surface mount 22 , on which hinge line 48 the control surface mount 22 is hingeably arranged.
In this illustration at least part of a disrupting profile 24 is shown, which disrupting profile 24 moves parallel to a movement axis 26 during hinging movement of the mount 22 . Consequently, in the limit switching device 10 in an extreme position a contact or a signal is established so that a control unit 28 can detect this extreme position and can interrupt the drive of the motor 6 at least in one direction, towards the left-hand side in the plane of the illustration. When the other extreme position has been reached, at the right-hand side in the plane of the illustration, a contact or a signal with the other limit switching device 12 is established.
In FIG. 2 a lateral section view shows the interior design of the apparatus 2 . A gear shaft 30 projects through the plate 14 into the gear arrangement housing 16 where it drives a bushing 32 connected to the gear shaft 30 , which bushing 32 comprises a slot 34 at its side pointing away from the motor 6 . A second bushing 36 comprises a correspondingly formed projection 38 that is designed to engage the slot 34 in a flush manner. The second bushing 36 in turn is connected to a spindle 40 that moves an adjustment body 42 by engaging a spindle nut (not shown in this illustration). On the adjustment body 42 an adjustment lever 44 is arranged so as to be hingeable on a hinge axis 46 , with the side of the adjustment lever 44 , which side faces away from the adjustment body 42 , being hingeably connected to the control surface mount 22 . As shown in FIG. 1 , the control surface mount 22 is arranged so as to be hingeable on a hinge axis 48 formed on the linear guide 18 .
For guiding, the adjustment body 42 is formed in such a manner that it can be moved flush in a recess 50 of the linear guide 18 . To prevent movement extending laterally to the movement axis, as an example a pin 52 may be inserted into the adjustment body 42 after placement in the recess 50 , which pin 52 is guided in a corresponding slot 54 on the top or bottom of the linear guide 18 . The combination of a pin 52 and slots 54 furthermore defines a mechanical end stop, which in the case of defective or ineffectively-switched limit switching devices 10 and 12 by means of a hard mechanical end stop would prevent the control surface mount 22 from continuing to move.
In the exploded view of FIG. 3 , as an example, all the components of the apparatus 2 are shown in detail. A combination of the motor 6 and the gear arrangement 8 forms a functional unit on whose outer circumference two clamp-like mounting brackets 56 and 58 can be arranged, each comprising a circular recess, with said recesses corresponding to the external diameters of the motor 6 and of the gear arrangement 8 . At an eccentric position the two mounting brackets 56 and 58 each comprise a recess for receiving photoelectric barriers 60 and 62 as limit switching devices that may, for example, be bonded in those locations in the mounting brackets 56 and 58 . The mounting brackets 56 and 58 may, for example, in each case be screwed to, or clamped to, the motor 6 or the gear arrangement 8 with the use of a grub screw.
The gear arrangement 8 is to be attached to a plate 14 , for example with a screw-type connection. In its housing the gear arrangement 8 comprises a ring-shaped shoulder 64 that can be inserted into the circular opening 66 so as to be flush, and that centers the gear arrangement 8 relative to the plate 14 .
The shaft 30 of the gear arrangement 8 , which shaft 30 projects through the opening 66 , can be connected to a first bushing 32 , for example by a laterally inserted grub screw that in a non-positive manner clamps the bushing 32 to the gear shaft 30 . A second bushing bush 36 with a projection 38 can be inserted into a slot 34 incorporated in the first bushing 32 , so that consequently transmission of torque can take place, and at the same time a certain angular offset as well as an offset across the movement axis 26 can be compensated for.
By a shoulder 63 the spindle 40 driven by the second bushing 36 is rotatably held, by way of sliding discs 65 which are made, for example from bronze, relative to the linear guide 18 , and in that place can be made to engage a spindle nut 68 that can be positioned in a recess 70 of the adjustment body 42 . For receiving the sliding discs 65 , both the linear guide 18 and the gear arrangement housing 16 comprise correspondingly formed recesses 67 or shoulders. The bearing clearance of the spindle 40 can be set with compensating plates 69 that are individually adjustable by grinding or by other materials removing processes, which compensating plates 69 comprise a slot 71 through which they can easily be inserted from the outside and fastened in a partially undone screw connection between the linear guide 18 and the gear arrangement housing 16 . Furthermore, it is particularly advantageous if the spindle nut 68 is designed so that it can be slid into the recess 70 , because in this position easy exchange of a spindle nut 68 can be achieved, without there being a need to manufacture the adjustment body 42 anew. In order to achieve a particularly play-free longitudinal movement of the adjustment body 42 it may make sense to design the spindle 40 as a recirculating ball screw.
At its side facing away from the motor 6 and from the gear arrangement 8 the adjustment body 42 comprises two outwardly open slot-shaped recesses 72 that are arranged so as to be symmetrical to the movement axis 26 of the apparatus 2 , and that are designed to receive a lever 74 and to hingeably hold it. The adjustment lever 74 in turn is designed in such a manner that by its side facing away from the positioning body 42 it can be placed into a control surface mount 22 , which is held by an angle mount 20 of the linear guide 18 so as to be hingeable on a hinge axis 48 . In order to establish a hingeable connection, cylinder pins, bolts, screws or the like can be used.
Furthermore, on the adjustment body 42 a disrupting profile 24 is arranged, for example by way of a screw-type connection, so that when the adjustment body 42 moves the disrupting profile 24 also moves parallel to the movement axis 26 of the apparatus 2 . A disrupting 76 may be arranged in an outwardly open slot 78 of the disrupting profile 24 so that interruption of the photoelectric barrier 60 can take place. For operation of the photoelectric barrier 62 the disrupting profile 24 can comprise a similar device; as an alternative to this, operation of the photoelectric barrier 62 can take place in an inverse manner so that reaching an extreme position is detected only when the disrupting profile 24 leaves the photoelectric barrier 62 .
At the same time the disrupting profile 24 is designed, by means of a linear positioning encoder 80 , which can be connected to the linear guide 18 by way of a mounting bracket 82 , which comprises for example an angular design, to acquire the distance covered by the adjustment body 42 and thus by the disrupting profile 24 . Such acquisition takes place, for example, optically in a non-contacting manner. For this purpose the disrupting profile 24 can comprise a reference measuring tape with an optically acquirable gradation, which measuring tape may, for example, be bonded to the side of the disrupting profile 24 , which side faces the linear positioning encoder 80 . In order to transmit movement of the adjustment body 42 to the control unit 28 , a reference point transmitter 78 can be used which may be bonded to the top of the disrupting profile 24 and which transmits position data to a corresponding receiving unit of the control unit 28 .
FIG. 4 shows an apparatus 2 , which apparatus 2 is integrated in a wing 84 of an aircraft model and is connected to a control surface 86 . Attachment of the apparatus can take place by way of a screw-type connection by means of flanges 88 .
In addition, it should be pointed out that “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, it should be pointed out that characteristics or steps which have been described with reference to one of the above exemplary embodiments can also be used in combination with other characteristics or steps of other exemplary embodiments described above. Moreover, while at least one exemplary embodiment has been presented in the foregoing summary and detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents.
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An apparatus is provided for adjusting and locking a movable control surface, which includes, but is not limited to a rotatably held spindle, an adjustment body, a linear guide, a drive unit, a linear positioning encoder and a control unit. The adjustment body with the linear guide is slidably guided along a first movement axis, and the spindle is connected to the adjustment body for moving the adjustment body along the movement axis. The adjustment body is configured to connect to a control surface mount, and the linear positioning encoder and the drive unit are connected to the control unit. The latter is designed to adjust a predetermined actuating position of the adjustment body by rotation of the spindle with the drive unit and by comparing an actual position, detected by the linear positioning encoder, of the adjustment body with the predetermined actuating position.
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FIELD
The present disclosure relates to modular wall finishing systems. More particularly to a modular basement wall finishing system having a seamless wall structure.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Commercial wall systems are used for finishing many types of interior spaces. Typically these wall systems are installed between a floor and a ceiling surface using a large quantity of framing members. Additionally, when the wall system is installed, insulation is often used to increase thermal efficiency. The framing members and insulation create a complex installation process, increase cost, and inhibit removal for future use of the wall system in a different space or location.
Typically these systems are used in buildings having porous block or poured concrete walls that can retain unwanted moisture and wick the moisture into the living space. This unwanted moisture is often trapped in a confined space between the exterior walls and the interior walls which creates harmful mold. The mold and moisture eventually cause permanent damage to the interior walls, framing members, and insulation which prevents reuse and requires replacement of these components.
Therefore, there has been and continues to be a need for a modular wall system that has little complexity and provides moisture and mold resistant qualities as well as improving thermal efficiency.
SUMMARY
The present disclosure is directed to a seamless wall finishing system, having a series of wall panels which are spaced apart from the exterior walls. The spacing creates an air gap between the wall panels and the exterior walls to provide an airflow passage between the exterior wall and the backside of the wall panels.
In another embodiment of the present disclosure, a mold resistant non-organic thread or yarn wall covering that can include nylon, fiberglass, polyester, etc. is adhered to a central portion of a first surface of each of a plurality of wall panels. A perimeter of the first surface of each of the plurality of wall panels has an uncovered area such that when a first of the plurality of wall panels is mounted adjacent a second of the plurality of wall panels a vertically extending seam is defined. A mold resistant non-organic thread or yarn seam tape is then adhered to the vertically extending seam.
A method of assembling a modular basement wall finishing system is also provided.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a partial cross-sectional view of the modular basement finishing system according to the present disclosure;
FIG. 2 is a schematic view of the modular basement finishing system illustrating an air gap and ventilation system according to the principles of the present disclosure;
FIG. 3 is a partial cross-sectional view of the modular basement finishing system further illustrating the air gap and ventilation system depicted in FIG. 2 ;
FIG. 4 is a schematic view of the modular basement finishing system illustrating an alternative air gap and ventilation system;
FIG. 5 is a plan view of a series of adjoining wall panels illustrating the “H-Clip” attachment method; and
FIG. 6 is a fragmentary side elevation view of a portion of the modular basement finishing system showing the application of the seam tape into a vertically extending seam created by adjoining sheets of mold resistant non-organic thread or yarn wall coverings.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
With reference to FIG. 1 , a modular basement finishing system is depicted generally by reference number 10 . As will be discussed, the modular basement finishing system 10 is designed to be erected and detachably secured between a floor structure 20 and a ceiling structure 22 . The modular basement finishing system 10 may be spaced away from the basement foundation wall 12 which may allow air to flow through an airflow passage 24 between the basement foundation wall 12 and the modular basement wall finishing system 10 . It is understood that the modular basement finishing system 10 may be spaced away from the basement foundation wall 12 at an appropriate interval to achieve a desired airflow. In a preferred embodiment, an elongated floor railing 18 may be detachably secured to the floor structure 20 using fasteners 17 . The elongated floor railing 18 is typically constructed of metal or any other suitable materials. An elongated ceiling railing 16 may be detachably secured to a ceiling structure 22 using fasteners 17 . The elongated ceiling railing 16 is typically constructed of metal or any other suitable material. The ceiling structure 22 may include joists, rafters, or any other suitable structure for retaining fasteners 17 . The elongated ceiling railing 18 is typically constructed of metal angle iron or any other suitable material. A wall panel 14 is vertically positioned adjacent the elongated floor railing 18 and the elongated ceiling railing 16 . The wall panel 14 may be detachably secured to the elongated ceiling railing 16 using fasteners 17 . Additionally, the wall panel 14 may be detachably secured to the elongated floor railing 18 using fasteners 17 . It is understood that the wall panel 14 may also be detachably secured to the elongated floor railing 18 and the elongated ceiling railing 16 using any method of detachably securing wall panels 14 known in the art.
With reference to FIGS. 2 and 3 , the modular basement finishing system may include an air inlet aperture 26 in communication with the airflow passage 24 that is provided between the foundation wall 12 and wall panels 14 . Although the air inlet aperture 26 may be located in an exterior wall 12 as depicted in FIG. 2 , the air inlet aperture 26 may also be located in a wall panel 14 , the ceiling structure 22 or any other suitable area for locating an air inlet aperture 26 to allow communication with the airflow passage 24 . The modular basement finishing system 10 may further include an air outlet aperture 28 in communication with the airflow passage 24 . Although the air outlet aperture 28 may be located in an exterior wall 12 as depicted in FIG. 2 , the air outlet aperture 26 may also be located in a wall panel 14 , the ceiling structure 22 or any other suitable area for locating an air outlet aperture 26 to allow communication with the airflow passage 24 .
The modular basement finishing system 10 may further include a dehumidifier 32 which may be in communication with the airflow passage 24 . The dehumidifier 32 may reduce the moisture from the airflow entering the airflow passage 24 . It is understood that a dehumidifier 32 may be any device suitable for removing moisture from the air. Although the dehumidifier 32 is shown on the outside of an exterior wall 12 , the dehumidifier 32 may be installed on either side of the wall panels 14 including within the airflow passage 24 . The dehumidifier 32 may also be installed anywhere suitable for maintaining communication with the air inlet aperture 26 . FIG. 2 further illustrates a blower 30 in communication with the airflow passage 24 and the dehumidifier 32 . The blower 30 may provide air to the dehumidifier 32 . The blower 30 may also be attached between the air inlet aperture 26 and the dehumidifier 32 . In this configuration the blower 30 may draw dehumidified air from the dehumidifier 32 or may force air through the dehumidifier 32 . Alternatively, the blower 30 may be integral to the air inlet aperture 26 or the dehumidifier 32 or connected to the dehumidifier 32 by any means known in the art. Additionally, FIG. 2 illustrates an exhaust blower 34 in communication with the airflow passage 24 . The exhaust blower 34 may be attached to the air outlet aperture 28 . Alternatively, the exhaust blower 34 may be integral to the air outlet aperture 28 or connected to the air outlet aperture 28 by any means known in the art.
With reference to FIG. 4 , another embodiment of the modular basement finishing system 10 is provided wherein the air inlet aperture 26 and the air outlet aperture 28 are located adjacently. A vertically extending baffle 15 may be installed between the exterior wall 12 and a wall panel 14 . The vertically extending baffle 15 may be positioned substantially between the air inlet aperture 26 and the air outlet aperture 28 and may provide an airflow barrier there between. The vertically extending baffle 15 may begin at the floor structure 20 and continue to the ceiling structure 22 , shown in FIG. 3 . The vertically extending baffle 15 may be made of any suitable material known in the art. The vertically extending baffle 15 may adhere to the wall panel 14 and the exterior wall 12 . Alternatively, the vertically extending baffle 15 may be fastened or sealed to the wall panel 14 and the exterior wall 12 . The vertically extending baffle 15 may provide uni-directional airflow through the airflow passage 24 . The vertically extending baffle 15 may also be formed integrally to the wall panel 14 . The vertically extending baffle 15 may also attach to the elongated ceiling railing 16 and the elongated floor railing 18 .
Additionally, FIG. 4 illustrates an elbow connector 36 attached to the air outlet aperture 28 and the dehumidifier 32 . The elbow connector 36 may provide a closed loop connection to allow the dehumidifier 32 to reuse the air exiting the air outlet aperture 28 where it is desirable to reduce the workload of the dehumidifier 32 in high humidity conditions. Although the air exiting the air outlet aperture 28 may have a greater moisture content than the air entering the air inlet aperture 26 , it may be a lower moisture content than atmospheric air and thus reduce the workload and energy consumption of the dehumidifier 32 and the blower 30 where an open loop system is used. It should be understood that the closed loop configuration may allow the dehumidifier 32 and the blower 30 to be configured in any orientation between the air inlet aperture 26 and the air outlet aperture 28 . Additionally, where the air inlet aperture 26 and the air outlet aperture 28 are formed, for example in one of the wall panels 14 , the dehumidifier 32 , blower 30 , elbow connector 36 , and exhaust blower 34 can be also be located inside of the interior space created by the wall panels 14 . The dehumidifier 32 , blower 30 , elbow connector 36 , and exhaust blower 34 can be located anywhere that is suitable for communicating with the airflow passage 24 , for example in a utility closet or a mechanical room.
With reference to FIG. 5 , each wall panel 14 may have an inner foam structure 64 which may provide each wall panel 14 with an insulation value which may increase the temperature and comfort level of a basement or any other suitable type of building. The inner foam structure 64 can be made from material such as closed cell foam or any other suitable material known in the art. The inner foam structure 64 may have mechanical properties capable of loading the wall panel 14 with additional structure, for example, shelving and audio/video equipment. The inner foam structure 64 may have apertures 62 formed therein which may receive an electrical conduit which may supply electricity to outlets and switches in each of the wall panels 50 . Each wall panel 14 may have an aperture 62 formed in substantially the same location so that electrical conduit can be received by the aperture 62 formed in each wall panel 14 . The aperture 62 may be suitable to receive other mechanical or electrical hardware as desired. For example, plumbing conduit may also be installed in the aperture 62 .
The inner foam structure 64 may have a first mineral board 58 applied to a first surface of the inner foam structure 64 . The inner foam structure 64 may also have a second mineral board 60 applied to a second surface of the inner foam structure 64 . The first mineral board 58 and the second mineral board 60 may be made of any suitable materials known in the art. The first mineral board 58 and the second mineral board 60 may be adhered to the inner foam structure 64 , attached with fasteners or secured using any other suitable means known in the art. The first mineral board 58 and the second mineral board 60 may be structurally reinforced with a fiberglass mesh or any other suitable reinforcement material.
A panel biscuit or H-clip 56 may be used to secure adjacent wall panels 14 . The H-clip 56 allows the adjoining wall panels 14 to be rigidly attached and may eliminate the need for reinforcing frame members. The H-clip 56 may be made from metal, plastic, composite or any other suitable material. The H-clip 56 may be configured in any orientation that may secure adjoining wall panels 14 . A first pocket 52 in the wall panel 14 may be formed by sliding a knife in between the inner foam structure 64 and the back side of the first mineral board 58 . Next, a second pocket 54 may be formed in the wall panel 14 by sliding a knife in between the inner foam structure 64 and the back side of the second mineral board 60 at substantially the same vertical position as the first pocket 52 . The first end 57 of the H-clip 56 may be installed in the first pocket 52 and the second pocket 54 . Next, a first pocket 52 and a second pocket 54 of an adjacent panel are formed to receive a second end 59 of the H-clip 56 . The adjoining wall panels 14 are then abutted such that the second end 59 of the H-clip 56 is inserted into the first pocket 52 and the second pocket 54 of the adjacent wall panel 14 . The wall panels 14 are detachably secured to the elongated floor railing 18 and the elongated ceiling railing 16 using fasteners 17 . The wall panels 14 can be detached by removing the fasteners 17 and separating the adjoining wall panels 17 . A single H-clip 56 may also be pre-installed on one side of each wall panel 14 before the wall panels are shipped to the work site to reduce the quantity of on-site installation steps.
With reference to FIG. 6 , each wall panel 14 may have a pre-applied mold resistant nylon yarn wall covering 38 (wall covering). The wall covering may begin at the ceiling structure 22 and terminate at any desired location such as a chair rail trim or base molding trim (not shown). The wall covering 38 may have an anti-microbial film or may have an anti-microbial paint. The wall covering 38 may also use any suitable material for reducing moisture build up and mold formation known in the art. The wall covering 38 may have a grain pattern and a gloss level that may be designed to be aesthetically pleasing and functional. The grain pattern and the gloss level may provide functionality by hiding scuff marks, for example. Further, the seam tape 40 may have similar or substantially the same grain pattern and gloss level as the wall covering 38 . The seam tape 40 may provide a seamless appearance when adhered between adjacent wall coverings 38 and 42 or patching a damaged area by cutting and removing the damaged area, then creating a patch and adhering it to the wall panel 14 . The wall covering 38 may have a series of non-organic thread or yarn strands embedded therein. The series of non-organic thread or yarn strands may also be disposed on the first surface of the wall covering 38 . The non-organic thread or yarn strands may form or impart a grain pattern on the wall covering 38 and the seam tape 40 . The grain pattern may aid the installer in joining the terminal edges of the seam tape 40 to the terminal edges of the wall covering 38 . The non-organic thread or yarn strands may also provide a uniform vertical line if trimming of the wall covering 38 or the seam tape 40 becomes necessary, for example, where a partial wall panel 14 is installed adjacent a full wall panel 14 , the wall covering 38 will need to be removed from one side of the partial wall panel 14 to create a first uncovered area 44 . The seam tape 40 may be applied over the joint 48 created by adjoining wall panels 14 and to the first uncovered areas 44 and 46 . The seam tape 40 may be any width suitable to cover the first uncovered areas 44 and 46 . The seam tape 40 may have an anti-microbial film or may have an anti-microbial paint. The seam tape 40 may contain any suitable material for reducing moisture build up and mold formation known in the art. The seam tape 40 adhesive may be heat and pressure sensitive or self-adhering.
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A seamless wall finishing system has a plurality of wall panels which are spaced apart from an exterior wall. The spacing creates an air gap which provides an airflow passage between the exterior wall and the second surface of the wall panels. The wall panels have a mold resistant non-organic thread or yarn wall covering which is adhered to a central portion of a first surface of each of the wall panels. The wall panels define a pair of uncovered areas on opposite sides of each of the plurality of wall panels. A vertically extending seam is created between adjacent wall panels which is filled with a seam tape made from the mold resistant nylon yarn wall covering. An air circulation system is provided for circulating air behind the wall panels. A method of assembling the modular basement wall finishing system is also provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to spill containment systems, and more particularly, pertains to deployable devices for confining cargo leaking from watercraft, such as for example, oil escaping from a damaged tanker.
2. Description of the Prior Art
A certain amount of risk of spillage is always associated with the transport of cargo by ships across bodies of water. Spillage sometimes occurs during off-loading and on-loading operations or while a vessel is underway as a result of damage incurred in a collision or due to running aground. Such spillage can have catastrophic consequences when the spilled cargo is hazardous, especially when large quantities thereof stand to be lost. The environmental impact is devastating when a supertanker spills a load of crude oil near an ecologically sensitive coastline.
Various systems have been devised to prevent or minimize spillage, contain spillage, recover spillage, and/or treat spillage. None provide an effective and economically feasible means to reduce the environmental impact to an acceptable level. The magnitude of effort required to recover or treat an uncontained spill defies solution while the logistical impossibility of addressing all possible contingencies renders absolute prevention similarly unattainable. Efforts directed to containment or confinement would therefore appear to offer the most potential as an effective and feasible solution. However, no systems have been disclosed that are capable of positively containing a spill, are quickly and easily deployed and are readily implemented on an industry-wide basis in a relatively economical fashion.
The system currently most often relied upon requires the placement of floating booms around the perimeter of a spill. While this may be effective to prevent a film or a thin layer of oil from spreading, it is physically impossible for such a system to contain a significant volume of spillage. Although oil floats on water, it freely passes underneath such a boom once sufficient oil is present to float the boom. Additionally, rough water can easily cause oil to be pushed underneath or thrown over such a containment system. The fitment of a curtain-like structure extending a short distance below floating boom does enhance the efficacy of such a system but nonetheless fails to provide a positive containment system.
SUMMARY OF THE INVENTION
The present invention provides a system for containing cargo spilling from a ship. The system is especially well suited for containing oil leaking from a tanker. The device according to the present invention is stowable in relatively compact form, is quickly deployable and serves to positively contain fluid escaping from the ship until a clean-up operation can be undertaken. Moreover, the system is relatively inexpensive and therefore conceivably implementable on an industry-wide basis.
In deployed form a sealing boot tightly engages the ship's hull from a point above the waterline, across its bottom to a point above the waterline on the opposite side, a liner extends outwardly therefrom a substantial distance beyond the periphery of the ship, while the periphery of the liner is held afloat by a buoyant boom. A skirt affixed to the entire length of the boom is tethered to the deck of the ship.
The sealing boot consists of an inflatable tube structure having a line extending longitudinally therethrough. Inflation of the tube, once the line is tightly secured about the ship's hull, causes a seal to be achieved and effectively precludes the seepage of fluid between the boot and hull. The buoyant boom similarly consists of an inflatable tube structure and extends outwardly from the sealing boot along the entire periphery of the liner. Air hoses are provided to interconnect the inflatable tubes with an air source maintained on the ship. Prior to use, the entire device is maintained on a storage reel in a deflated and folded state preferably in position on the forward-most section of the deck. A second device, similarly stowed, may be maintained on the aftmost section of the deck. The devices are oriented on their respective storage reels such that the sealing boot is the first accessible component of the containment system.
In the event leakage is detected, the device stowed closest to the rupture or source of leakage is immediately deployed. The boot with attached boom, liner and skirt is pulled off the reel and dropped overboard while the ends of the line extending through the boot are carried, one on each side of the ship, to a point beyond the source of the leakage. The line is secured so as to take up all slack therein as it extends about the hull after which the boot is inflated. While the boot is being maneuvered into position, the remaining portions of the liner, boom and skirt are pulled off the reel and over the side of the ship. All tether lines attached to the skirt are secured on deck. Depending on sea and weather conditions, small support craft may have to be employed to assist in the deployment of the containment system. Upon inflation of the floatation boom, the device is capable of positively containing fluid spilling from the ship. The tether lines are individually paid out to accommodate increases in the volume of the spillage. The device is of sufficient size to contain a substantial portion of the cargo carried by the ship.
Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the device of the present invention in its fully deployed form;
FIG. 2 is a cross-sectional view taken along lines 2--2 of FIG. 1;
FIG. 3 is a cross-sectional view taken along lines 3--3 of FIG. 1;
FIG. 4 is an enlarged cross-sectional view taken along lines 4--4 of FIG. 1;
FIG. 5 is an enlarged cross-sectional view taken along lines 5--5 of FIG. 1; and
FIG. 6 is an enlarged cross-sectional view of the system of the present invention in a deployed and partially filled condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The figures illustrate a preferred embodiment of the present invention adapted for use on an oil tanker. Two separate containment systems are maintained in a readily deployable condition, one near the bow of the ship and the other near the stern. When a leak is detected, the system nearest the source of the leakage is deployed to form an impermeable dammed area extending about the ship and capable of containing a substantial portion of the oil potentially lost from the ship until a clean-up operation can be undertaken.
FIGS. 1-3 illustrate the containment system of the present invention in its fully deployed state. In the pictured configuration the system is capable of containing oil leaking from a source 13 located in the forward portion of the ship's 14 hull 12. Sealing boot 16 sealingly engages hull 12 at a position just aft of the source 13 of leakage. Buoyant boom 18 is attached to sealing boot 16 at or above the waterline 15 and extends outwardly to define the outermost perimeter of the containment system. An impermeable liner 20 is contiguously affixed to sealing boot 16 as well as boom 18. Contiguously affixed to boom 18 is skirt 24, the periphery of which is tethered to the deck of the ship 14 via tether lines 22.
FIG. 4 provides an enlarged cross-sectional view of sealing boot 16 as it engages hull 12. The boot generally consists of an inflatable tubular structure of sufficient length to extend from above the waterline 15, on one side of ship 14 underneath hull 12 to above the waterline on the opposite side of the ship. Centrally located within boot 16 is sleeve 26 accommodating line 28 therein. End cap 30 enables the space within the tubular structure and outside sleeve 26 to be pressurized. Line 28 is of sufficient length to enable the position of boot 16 to be manipulated from deck and to allow the ends of the line 28 to be properly secured. Air hose 32 extends from within the tubular structure of boot 16 and is attachable to a source of pressurized air. FIG. 4 additionally shows buoyant boom 18 extending outwardly from boot 16 at or above waterline 15. Liner 20 is attached to both boom 18 as well as boot 16. Skirt 24 is similarly attached to boom 20 as well as a portion of boot 16.
FIG. 5 provides an enlarged cross-sectional view of boom 18. In the preferred embodiment of the liner 20, boom 18, and skirt 24 are formed from a single sheet of material. Folded and fused at 34 as shown, the structure provides two inflatable tubular cavities 36, 38 around the entire perimeter of the system. The edge of skirt 24 has eyelets 40 therein to facilitate attachment of the tether lines 22. Air hose 42 enables pressurized air to be conducted from a source (not shown) to the interior of cavities 36, 38.
The tanker 14 shown in FIG. 1 is outfitted with two separate and identical spill containment systems. Empty reel 44 had served to stow the system shown deployed. A second system is shown stowed on reel 46 in position near the ship's stern. Reels 44, 46 are of sufficient size to accommodate the entire boot 16, liner 20, boom 16 and skirt 24 assembly thereon in a folded and rolled up configuration, oriented such that boot 16 is the first accessible component.
The preferred material employed for the entire structure including boot 16, liner 20, boom 18 and skirt 24 is a PVC film. The material's tensile strength, its light weight and the capability of being fusion welded renders this material ideal for this application.
In use, upon detection of a leak, a determination must first be made as to whether the forward system or the aft system is nearest the source of the leakage. Once such a determination has been made, boot 16 is pulled off the nearest reel and dropped overboard while the ends of the line 28, one end on each side of the ship are carried into position beyond the source of the leakage. The line's ends are secured so as to take up all slack and firmly engage hull 12. Subsequently thereto the boot is inflated via air hose 32 causing the boot to sealingly engage the hull. While this is being accomplished, the rest of the liner 20 and boom 18 assembly is pulled off the reel and dropped overboard while the tether lines 22 are secured to the deck of the ship.
FIG. 6 illustrates a cross-section of the containment system shortly after deployment and before a significant amount of oil has escaped from the ship. All inflatable components are inflated, but since only a relatively small amount of oil has escaped, tether lines 22 hold boom 18 relatively close to the ship. A small quantity of water 54 is present within the containment system, said water having entered thereinto while boot 16 was being maneuvered into position and before said boot was inflated to sealingly engage the hull. Oil 50, escaping from the rupture 13, freely floats to the top 52 of the water level within the contained area and spreads out to the perimeter defined by boot 18. As more and more oil fills the dammed area, tether lines 22 are paid out to relieve the tension. The entire structure is of sufficient size such that the loads the tether lines 22, skirt 24, boom 18 and liner 20 are subjected to are well below the load limits of the individual components even when the system is serving to contain a substantial portion of the tanker's cargo of oil. A clean-up operation can be undertaken at any time, wherein the oil contained within the dammed area is pumped to any empty tanker. Alternatively, the spilled oil may be pumped to the leaking tanker's own ballast holds.
While a particular form of the invention has been illustrated and described, it will also be apparent to those skilled in the art that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited except as by the appended claims.
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A system carried aboard tankers which upon deployment serves to positively contain oil leaking therefrom. A boot sealingly engages the hull while a buoyant boom supports the periphery of an impermeable liner attached to the boot. A skirt extending from the boom is tethered to the deck of the vessel. The entire system is normally maintained in a compact, folded form spooled up on a storage reel which is positioned on the deck of the tanker.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is based on, and claims priority from, Korean Application Serial Number 10-2004-0063157, filed on Aug. 11, 2004, the disclosure of which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to an engine system and, more particularly, to a method of determining the amount of fuel injection in response to the state of an airflow sensor.
BACKGROUND OF THE INVENTION
[0003] Typically an engine combusts fuel in a combustion chamber formed by the cylinder, cylinder head, and piston that reciprocates in the cylinder. Explosion force from the combustion rotates a crankshaft through a connecting rod that is connected to the piston and, thereby, converts thermal energy into mechanical energy. The combustion chamber is mounted with an intake pipe to provide the air-fuel mixture, and an exhaust pipe to discharge burned gas. The intake pipe is typically installed with a throttle valve and airflow sensor.
[0004] An Electronic Control Unit (ECU) is programmed to decide, according to an amount of air detected via an airflow sensor, an appropriate amount of fuel for activating the engine. However, if vibration and reverse-flow are generated in the intake pipe of the engine, the output value of the airflow sensor can be inaccurate. Therefore, the airflow sensor should first be diagnosed as to whether it is in a reliable state, and if not, the fuel amount should be determined regardless of the air amount measured via the airflow sensor.
SUMMARY OF THE INVENTION
[0005] Embodiments of the present invention provide improved accuracy in determining a credible range of an airflow sensor. The present invention also increases the range where the amount of fuel injection can be determined by using an outputted value from the airflow sensor.
[0006] According to another embodiment, a method determines the amount of fuel injection into an engine system having a crank sensor and airflow sensor. The method includes computing the speed change in engine revolutions per minute (rpm) by detecting the engine rpm from the crank sensor. Next the method computes the speed change of an intake-air amount by detecting the intake-air amount from the airflow sensor. The method then compares the speed change of the engine rpm and the speed change of the amount of intake-air with reference values, respectively. Thereafter, and Electronic Control Unit (ECU) decides whether the diagnosis of the generation of vibration and reverse-flow in an intake manifold is required. If the diagnosis for the generation of vibration and reverse-flow in the intake manifold is decided to be required, the method executes a pre-established determination logic for the vibration and reverse-flow and determines whether the vibration and reverse-flow are generated in the intake manifold. If the vibration and reverse-flow are determined to occur in the intake manifold, then the method corrects the intake-air amount, which is restored before generation of the vibration and reverse-flow, in response to the present engine speed. Next, the method computes the present intake-air amount and decides the fuel injection amount by using the above computed intake-air amount instead of using the intake-air amount measured by the airflow sensor.
[0007] If it is determined that no vibration and reverse-flow occur in the intake manifold, the fuel injection amount is preferably determined by using the value measured via the airflow sensor. If the speed change of the engine rpm or the speed change of the intake-air amount exceeds a pre-established relevant reference value, then the method diagnoses whether the vibration and reverse-flow are generated in the intake manifold. Thus, according to a preferred embodiment, the diagnosis of generation of the vibration and reverse-flow is performed only if necessary.
[0008] According to another embodiment, the speed change of engine rpm is preferably calculated by computing a changed amount of time by subtracting a previous timer value from a present timer value and then multiplying the result by a time conversion constant. Next, the method restores the present timer value as the previous timer value and computes a changed amount of engine rpm by subtracting a previous engine rpm from a present engine rpm measured from the crank sensor. The present engine rpm is restored to the previous engine rpm and the speed change of the engine rpm is computed by dividing the changed amount of engine rpm by the changed amount of time.
[0009] According to an embodiment, the speed change of the amount of intake-air is preferably calculated by computing a changed amount of time. The changed amount of time is computed by subtracting a previous timer value from a present timer value and then multiplying the result by a time conversion constant. Next the present timer value is restored to the previous timer value and a changed amount of intake-air is computed by subtracting a previously measured intake-air amount value from a present intake-air amount value measured via the airflow sensor. The present intake-air amount value is restored as the previous intake-air amount value and the speed change of the intake-air amount is computed by dividing the changed amount of intake-air by the changed amount of time.
[0010] Whether the diagnosis for the generation of the vibration and reverse-flow in the intake manifold will be performed is decided by comparing, on the basis of a pre-saved reference speed change table of the engine rpm, the above computed speed change of the engine rpm with a reference speed change of the engine rpm according to the engine rpm and engine load. Next, on the basis of a pre-saved reference speed change table of the intake-air amount, the above computed speed change of the intake-air amount is compared with a reference speed change of the intake-air amount according to the engine rpm and engine load. Thereafter, the method decides whether the diagnosis of the generation of vibration and reverse-flow in the intake manifold is required according to the result of the logical sum of each of the above comparisons. Thus, the diagnosis for the generation of the vibration and reverse-flow is performed only if necessary.
[0011] According to another embodiment, the determination of the generation of the vibration and reverse-flow in the intake manifold is preferably performed by determining whether a negative value is obtained when the speed change of the engine rpm is multiplied by a conversion constant that converts the speed change of the engine rpm into the speed change of the intake-air amount according to the driving state of an engine. Then the value is multiplied by the speed change of the intake-air amount. An absolute value of this value is obtained by subtracting the speed change of the intake-air amount from the multiplication of the speed change of the engine rpm with the conversion constant. Thereafter, the above absolute value is compared with an allowance value of the speed change of the engine rpm and the speed change of the intake-air amount according to the driving state of an engine. If the above multiplied value is a negative value and the absolute value is larger than the allowance value the method determines that the vibration and reverse-flow are generated in the intake manifold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a better understanding of the nature and objects of the present invention, reference should be made to the following detailed description, read in conjunction with the accompanying drawings, in which:
[0013] FIG. 1 is a flowchart of a method for determining an amount of fuel injection using an airflow sensor in an engine system according to an embodiment of the present invention;
[0014] FIG. 2 is a flowchart of a method for computing a speed change of an intake-air amount of FIG. 1 ;
[0015] FIG. 3 is a flowchart of a method for computing a speed change of an engine rpm of FIG. 1 ;
[0016] FIG. 4 is a block diagram of a logic that determines whether diagnosis for generation of a vibration and reverse-flow in an intake manifold of FIG. 1 is required; and
[0017] FIG. 5 is a block diagram of a logic for determining generation of vibration and reverse-flow in an intake manifold of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] As illustrated in FIG. 1 , revolutions per minute (rpm) of an engine are detected from a crank sensor (S 1 ). A speed change of the rpm is calculated (S 2 ) according to an embodiment of the present invention. An intake-air amount is detected via an airflow sensor (AFS) (S 3 ) and then the speed change of the intake-air amount is calculated (S 4 ). The speed change of the engine rpm, as well as, the speed change of the intake-air amount are compared with the reference values, respectively, and whether a determination logic for the generation of vibration and reverse-flow in the intake manifold will be performed is determined (S 5 ).
[0019] If the speed change of the engine rpm or the speed change of the intake-air amount exceeds the reference value as a result of step 5 , a determination logic for the generation of the vibration and reverse-flow in the intake manifold is performed (S 6 ). If the vibration and reverse-flow are determined to occur in the intake manifold from step 6 (S 7 ), the intake-air amount (restored before the generation of the vibration and reverse-flow) is corrected to the present engine speed and the present intake-air amount is calculated (S 9 ). Next, the fuel-injection amount is determined by using the above calculated intake-air amount instead of using the intake-air amount measured by the AFS (S 10 ). However, if it is determined that no vibration and reverse-flow are generated in the intake manifold in step 7 , the amount of fuel injected in step 10 is determined by using a value measured via the AFS (S 8 ).
[0020] Calculation of the speed change of the intake-air amount, which is depicted in step 4 of FIG. 1 , is performed in the order described in FIG. 2 . A changed amount of time (Delta_Time) is computed (S 11 ) by subtracting a previous timer value (Timer_Old) from a present timer value (Timer) and then multiplying it by a time conversion constant (Time_Constant). The present timer value (Timer) is stored in a memory, at step (S 13 ). A changed amount of intake-air (Delta_Charge) is computed by subtracting a previously measured intake-air amount value (Charge_Old) from a present intake-air amount value (Charge) measured by the AFS, at step (S 15 ). The present intake-air amount value (Charge) is stored in a memory (S 17 ). The speed change of intake-air amount (D_Charge) is computed by dividing the changed amount of intake-air (Delta_Charge) by the changed amount of time (Delta_Time), at step (S 19 ).
[0021] According to an embodiment of the present invention, a calculation method for the speed change of the engine rpm, depicted in step 2 of FIG. 1 , is performed in the order described in FIG. 3 . A changed amount of time (Delta_Time) is computed (S 12 ) by subtracting a previous timer value (Timer_Old) from a present timer value (Timer) and then multiplying it by a time conversion constant (Time_Constant). The present timer value (Timer) is stored in a memory (S 14 ). A changed amount of the engine rpm (Delta_RPM) is then computed at step ( 216 ) by subtracting a previous engine rpm (RPM_Old) from a present engine rpm (RPM) measured via the crank sensor. The present engine rpm (RPM) is stored in a memory, at step (S 18 ). The speed change of engine rpm (D_RPM) is computed by dividing the changed amount of the engine rpm (Delta_RPM) by the changed amount of time (Delta_Time), at step (S 20 ).
[0022] Referring now to FIG. 4 , in order to determine whether the diagnosis for the generation of the vibration and reverse-flow in the intake manifold according to the driving state of an engine is required, a reference speed change of the engine rpm according to the engine rpm and engine load is calculated on the basis of a pre-saved reference table 10 of the speed change of engine rpm. Next, the above reference speed change of the engine rpm is compared in a comparator 12 with the speed change of the engine rpm computed in FIG. 2 . Likewise, in order to determine whether the diagnosis for the generation of the vibration and reverse-flow in the intake manifold according to the driving state of an engine is required, the speed change of the intake-air amount computed in FIG. 3 is compared, on the basis of a pre-saved reference table 11 of the speed change of intake-air amount, in comparator 12 with a reference speed change of the intake-air amount according to the engine rpm and engine load. Next, whether the diagnosis of the generation of the vibration and reverse-flow in the intake manifold will be performed is determined according to the result of the logical sum of each of the above comparisons in an OR logic 13 . Thus, when the speed change of the engine rpm or the speed change of the intake-air amount exceeds the reference value, the determination logic for the generation of the vibration and reverse-flow in the intake manifold is executed.
[0023] According to an embodiment of the present invention, the logic of FIG. 4 is performed because performing the determination logic for the generation of the vibration and reverse-flow at all times is inefficient to the function of the engine controller. Therefore, the allowable speed change of the engine rpm and the speed change of the intake-air amount per each engine operation region are pre-set in tables. If the speed change of the engine rpm or the speed change of the intake-air amount is generated at the substantial present engine operation range, the intake-air amount measured via the AFS is preferably used in place of performing the determination logic for the generation of the vibration and reverse-flow in the intake manifold.
[0024] Referring now to FIG. 5 , as per a first condition logic 24 of determining the generation of the vibration and reverse-flow in the intake manifold, it is determined whether a negative value is obtained, on the basis of a conversion constant table 21 , when the speed change of the engine rpm is multiplied by a conversion constant that converts the speed change of the engine rpm into the speed change of the intake-air amount according to the driving state of an engine and then is multiplied by the speed change of the intake-air amount. If the above multiplied value is negative, then the directions of the speed change of the engine rpm and the speed change of the intake-air amount are assumed to be opposite to each other and the vibration and reverse-flow are determined to occur in the intake manifold. According to a second condition logic 25 of determining whether the vibration and reverse-flow are generated in the intake manifold, an absolute value is obtained by subtracting the speed change of the intake-air amount from the multiplication of the engine rpm with a conversion constant. Then, the absolute value is compared with an allowance value of the speed change of the engine rpm and the speed change of the intake-air amount according to the driving state of an engine. If the absolute value is larger than the allowance value, the vibration and reverse-flow are determined to be generated in the intake manifold.
[0025] In case both first and second condition logics 24 and 25 are satisfied simultaneously, the vibration and reverse-flow are determined to occur in the intake manifold. However, although the speed change of the engine rpm and the speed change of the amount of intake-air are different from each other in the first condition, if the difference is small, then it is determined that no vibration and reverse-flow are generated in the second condition.
[0026] The credible range of the AFS limited by the vibration or reverse-flow of the intake-air is measured by the change rate of the AFS and change rate of the engine speed. The air amount is calculated only at the region where the vibration is generated. In the regions without vibration, the signal of the AFS is used, thereby enabling to increase the range using the AFS and improving the accuracy of determining the credible range of the AFS.
[0027] As apparent from the foregoing description of the present invention, there is an advantage in that the accuracy for determining the reliable range of the AFS in determining the amount of fuel to be injected is improved. Further, the range in which the fuel injection amount is determined by using the AFS can be increased.
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Determining a fuel injection amount of an engine system having a crank sensor and airflow sensor includes computing a speed change of engine revolutions per minute and computing a speed change of an intake-air amount. Comparing the speed change of the engine rpm and the speed change of the intake-air amount with reference values, and if vibration and reverse-flow are determined to occur in the intake manifold, correcting the intake-air amount into the present engine speed and computing the present intake-air amount. The fuel injection amount is then determined by using the above computed intake-air amount. This improves the accuracy of determining the credible range of the airflow sensor and increases the range using the airflow sensor.
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